e l e c t r i c

d u c t h e a t e r s

open coil finned tubular explosion-proof &

corrosion resistant
Introduction

HEATREX designs and manufactures commercial and industrial electric heating and control systems

that set the industry standard for excellence. The company’s heating solutions reflect more than 80

years of innovation, product quality and efficient service. Our custom design software enables our

representatives to respond to your requests for pricing and sizing of open coil and finned tubular

duct heaters within minutes. With this software, your local HEATREX representative becomes the

source for certified prints, wiring diagrams — complete submittal information.

Our heaters and controls range from the simplest standard duct heater to the most sophisticated,

custom designed comprehensive system. HEATREX’s attention to detail and rigorous testing give

worldwide customers premium products that they receive quickly and at a fair market price.

For your nearest HEATREX representative call 314-333-5500 or

visit www.heatrex.com
 Contents

Choosing Open Coil or Finned Tubular Design Custom Duct Heaters

32 Special Applications
Specific Requirements
33 Round Duct Construction
3 Calculating KW Requirements
34 Duct Heaters for Wet, Dusty and Corrosive Areas
3 Static Pressure Drop
35 Bottom Mounted Terminal Box
4 Minimum Velocity
35 Insulated Terminal Box
4 Maximum Velocity
35 Pressure Plates
5 Airflow Uniformity
36 Protective Screens
6 Multiple Heaters in the Duct
36 Unheated Sections
6 Clearance
36 Construction for Lined Ducts
7 UL and NEC Requirements
37 Slip-and-Drive Construction
7 International Requirements
37 Remote Panelboard
Installation Information 37 Minimum & Maximum Duct Dimensions
8 Heater Installation 39 Open Coil Custom Heater – Sample Specification
8 Field Wiring 40 Finned Tubular Custom Heater – Sample Specification
Standard Control Options Explosion-proof Duct Heaters
10 Internal Wiring 41 Safety
10 Control Option G — Basic 41 Experience
10 Control Option J — Pneumatic 41 Complete Product Line
11 Control Option K — Proportional 41 Applications
12 Thermostats 41 Use of Electric Heaters in Hazardous Areas
Construction – Electrical 42 National Electrical Code Classification
14 Bi-Metallic Thermal Cutouts 42 Class
14 Linear Thermal Cutouts 42 Division
15 Airflow Switch 43 Group
15 Fan Relay 44 Engineering Information
16 Magnetic Contactors 44 Airflow Requirements
16 Fuses 45 Comparison Chart
16 Control Transformer 227 Series Explosion-proof Duct Heaters
17 Disconnect Switch 46 Standard Construction
17 Pilot Lights 46 Installation
17 Pilot Switch 47 Temperature Control
17 Pneumatic/Electric (PE) Switches 48 Standard Heater Listing
18 Electronic Controls 49 Custom Options
18 SCR Power Controllers 50 How to Order
19 Step Controllers (Sequencers) 50 Sample Specification
20 Step Controllers (Microprocessor-based)
21 Vernier Proportional Control
220 Series Explosion-proof Duct Heaters
51 Standard Construction
21 Thermostats/Inputs for Electronic Controls
51 Control Options
Construction – Mechanical 51 Installation
22 Slip-in Heaters 52 Custom Options
22 Flanged Heaters 53 How to Order
22 Zero Clearance Construction 53 Sample Specification
23 Physical Standards
Custom Explosion-proof Duct Heaters
Standard Duct Heaters – Open Coil 54 Construction
24 HUA Slip-in and HUP Flanged Heaters 55 How to Order
24 KW Ratings 55 Sample Specification
24 Frame Sizes 56 Typical Wiring Diagrams
25 Sizes and Maximum KW Ratings
26 Detail Dimensions
Limited Warranty
26 Voltage and Phase Other HEATREX Products
26 Control Circuit Options & Special Features
26 Number of Heating Stages
27 Special Features
31 HUA/HUP – Sample Specification

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 Choosing Open Coil
Standard Control or Finned Tubular Design
Options

HEATREX manufactures both open coil (Figure 1) motor horsepower and makes it possible to retrofit
and finned tubular (Figure 2) heating elements and open coil heaters into existing systems without
can supply virtually any duct heater with either type of changing the fan motor.
element. While most simple space heating applications
Large Electrical Clearances – Generous electrical
use the open coil design, there are many applications
clearances between the coil and frame enable
where finned tubular construction is appropriate. The
open coils to withstand severe applications such as
following are the significant advantages of each type of
subway car heating, where voltages may exceed
construction.
750 volts.
Economy – On relatively small, low KW heaters (the
Open Coil bulk of typical space heating applications) the open
coil element is more economical. However, in
large, high KW heaters, finned tubulars are more
economical due to lower manufacturing costs.
Figure 1. Smaller Size – It is normally possible to get more
KW with open coil construction for a given face area.
Only the highest Grade A resistance wire (80%
nickel, 20% chromium) is used in all HEATREX duct Finned Tubular
heaters. This iron-free wire has a higher maximum
operating temperature, greater life, lower sag, less
resistance change and higher corrosion resistance
than other commonly used resistance wires. U-Bent
Using calibrated tooling, the coils are mechanically
crimped into stainless steel terminals. This
Straight
connection, along with 10-32 terminal threads and
stainless steel connection hardware, insures cool,
minimum resistance, trouble free terminations. Two-Pass
An extended shank on the terminal places the critical Figure 2.
resistance coil-to-terminal connection well out into
the airstream to keep it cool even in applications
Finned tubular elements are designed and built by
where up to 1” of interior insulation is used in the
HEATREX to meet the requirements of each job.
duct.
Length, wattage, voltage and element style are
Both terminal insulators and coil support insulators engineered to give the most economical package.
are fabricated from high-temperature ceramic. Their
All elements consist of a Grade A coil (80% nickel,
design and method of installation enable them to: 1)
20% chromium), precisely centered in a stainless
absorb both mechanical and thermal loading without
steel tube which is filled with granular magnesium
chipping or cracking and 2) easily withstand high
oxide. The entire assembly is compacted to
voltage dielectric tests.
maximize both the heat transfer and dielectric
Element Temperature – The open coil element properties of the magnesium oxide. After compaction
releases its heat directly into the airstream. As a the tube measures 0.475” (12 mm) O.D., an
result, the open coil runs cooler than the coil in the unusually large diameter providing sufficient
finned tubular element which is isolated from the air insulation for operation up to 600 volts.
by insulation and a metal sheath.
A stainless steel fin is helically wound onto the tube
Low Pressure Drop – Because of the high to increase its heat transfer surface.
percentage of open space across the heater, open
HEATREX has standardized on stainless steel for
coils have very low pressure drop as compared to
its finned tubular elements because of its superior
finned tubular heaters. This can result in reduced fan
resistance to moisture and corrosion.

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 Specific Requirements

Straight, Two-Pass and U-Bent elements are Calculating KW Requirements

furnished with mounting flanges, making them
Once the volume of airflow (CFM – in cubic feet per
individually removable through the terminal box.
minute) and the required temperature rise
Safety – Because the heating coil is completely (∆T – in degrees F) through the heater are known,
encased in a grounded metal sheath, shock hazard the required kilowatt rating (KW) of the heater can
due to accidental contact with the coil is eliminated. be determined from the formula:
Heaters installed close to a register, grille, or access
( Liters/Second
door should either use finned tubular construction or KW = CFM x ∆T°F KW = x ∆T°C
(
an open coil unit with a protective screen. 3193 837

Airflow Contamination – If airborne contamination, Where the desired heating capacity in BTU/Hr is
such as dirt or dust, builds up on open coil elements known, the KW is determined from the following
during shutdown periods, the elements can short out. formula:
Finned tubular elements, with their insulated coils, KW = BTU/Hr
eliminate this problem. Furthermore, upon start-up, 3412
a finned tubular heater which has been exposed to
droplets of water in the airstream (e.g. immediately
downstream from a spray type humidifier, a cooling
coil, or a fresh air intake) cannot short to ground as
open coils can when support bushings are wet.
Serviceability – In the unlikely event of element
failure, it is easier to replace individually mounted
finned tubular elements than open coil elements.
Mechanical Stability – Finned tubular elements are
more rugged than open coils. They will withstand
more physical abuse.
Airflow Uniformity – Finned tubular duct heaters
tend to be more tolerant of nonuniform airflow
conditions. Heat conducted along the element
length reduces or eliminates hot spots resulting from
nonuniform airflow. With open coil heaters, it may be
necessary to use a pressure plate to compensate for
bad airflow conditions.
Controllability – Because of their relatively high
thermal inertia, finned tubular elements controlled
with on/off thermostat systems provide more precise Figure 3.
control. Furthermore, finned tubular elements
cycle at a reduced rate, thus increasing the life
of the power components such as contactors. Static Pressure Drop
Nevertheless, when SCR controllers are used, Static pressure drop through an open coil heater is
equally precise control can be obtained with either quite low and, in most cases, can be ignored when
construction. calculating system pressure drop. The pressure drop
across a finned tubular heater is greater than across
an open coil. However, if pressure plates must be
added to an open coil, the pressure drop over the
open coil far exceeds the drop over a finned tubular
heater. The curves in Figure 3 give data for all three
constructions.

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 Standard Requirements
Specific Control Options

Minimum Velocity
Electric heaters differ from steam or hot water coils
in that the heat output is constant as long as the
heater is energized. Therefore, sufficient airflow must
be provided to prevent overheating and nuisance
tripping of the thermal cutouts. The minimum
required velocity is determined from Figure 4A or 4B
on the basis of entering air temperature and KW per
square foot of cross sectional duct area.
The maximum air inlet temperature for open coil
heaters is 100°F (38°C) and for finned tubular
heaters is 80°F (27°C).
Example: Determine whether the minimum air
velocity requirement is met for a 10 KW open
coil heater installed in a 24” wide x 12” high duct
operating with 1000 cubic feet per minute (CFM) of
air at a maximum inlet temperature of 65°F:
1. Duct Area = 24” x 12”/144 = 2 sq. ft.
2. KW per square foot = 10 KW/2 sq. ft. = 5.
3. Go to Figure 4B. Use top curve (below 80°F inlet
air).Find 5 KW per square foot on the vertical axis.
Read minimum velocity required, which in this
case is 310 feet per minute (FPM).
4. Heater air velocity = 1000 CFM/2 sq. ft. = 500 FPM.
Since 500 FPM exceeds the minimum, this
installation is safe. Consult your local HEATREX
representative for assistance if you do not have
sufficient air velocity.
Maximum Velocity
High velocity airflow is not normally encountered
in typical commercial HVAC applications, when
installing open coil duct heaters into velocities over
1200 feet per minute contact your local HEATREX
representative.

16 32

30

14 28
KW PER SQUARE FOOT DUCT AREA

KW PER SQUARE FOOT DUCT AREA

26

IR
TA
12 24

LE
° IN
22

80

R
AI
10 20

T
LO

LE
IR
IN
BE
18 A
0° T
LE
°-9

N
8 16 °I
81

00
° -1
14
91
6 12

10

4 8

FINNED 6
TUBULAR OPEN COIL
2 CONSTRUCTION 4 CONSTRUCTION

0 0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 0 100 200 300 400 500 600 700 800 900 1000 1100 1200
MINIMUM AIR VELOCITY REQUIRED MINIMUM AIR VELOCITY REQUIRED
(FEET PER MINUTE) (FEET PER MINUTE)
Figure 4A. Figure 4B.

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 Specific Requirements

Airflow Uniformity
To prevent hot spots, airflow must be uniformly
distributed across the heater face. Figure 5 illustrates
typical heater misapplications which result in non-
uniform airflow. The heater’s UL Listing requires
that it not be installed closer than 4’ (122 cm)
downstream or upstream from a fan outlet, abrupt
transition, or other obstructions. Elbows or turns
must be located at least 4’ (122 cm) from inlet of the
heater and 2’ (61 cm) from outlet of the heater.
If such an installation cannot be avoided, consult
your local HEATREX representative for assistance.
We can provide a pressure plate, non-heated zones
or special low watt density coils to overcome these
problems. Final approval of such applications is up
to the local inspection authority.

Heater too close to elbow Heater partially blocked by filter or frame member

Heater adjacent to transition Heater too close to fan

Figure 5.

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 Standard Requirements
Specific Control Options

Multiple Heaters in the Duct Clearance

HEATREX heaters are designed to be used singly,
not in series in a duct. Since HEATREX heaters
can be furnished in virtually any size and KW rating,
series installation of heaters can be avoided.
For very large heaters, field installation and shipping
may be simplified by using two or more sections
designed for parallel installation, illustrated by
Figure 6. Each section, furnished in the flanged
design, has individual thermal cutouts. Terminal
blocks are provided to interconnect these cutouts in
the field. Sections rest stably one on top of the other.
Heaters more than 6’ (152 cm) high are normally
provided in sections, but larger single section
heaters can be provided. Consult your local
HEATREX representative for details.
HEATREX heaters are UL Listed for zero clearance
to combustible surfaces. Thus, there is no minimum
distance between combustible materials and the
section of duct housing the heater, or the heater
itself. However, the terminal box must be accessible
for servicing. The NEC requires a minimum
workspace at least 30” (76 cm) wide by 42” (107 cm)
deep for access to the heater terminal box. More
space is required for large heaters and for removal
of slip-in heaters which are over 42” long.
In addition, sufficient clearance must be provided
for convection cooling of all heaters with built-in
SCR power controllers (Figure 7). Allow at least 5”
(12.7 cm) of free air space around the cooling fins
extending from the heater terminal box. Enclosing
the fins in any fashion, insulating them, or preventing
them from being cooled by normal convection will
cause controller failure and void the heater warranty.

Figure 6. Figure 7.

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UL and NEC Requirements
All HEATREX electric duct heaters described in
this catalog meet the requirements of Underwriters
Laboratories (UL) and the National Electrical Code
(NEC) unless otherwise indicated.†
Heaters furnished with one of the Control Options
on pages 10 and 11 are automatically UL Listed and
meet NEC requirements. Custom designed heaters
must meet certain requirements to comply with UL
and the NEC. The areas of particular concern are
outlined below.
Overtemperature Protection – Duct heaters
must be supplied with both primary and secondary
overtemperature protection. All HEATREX heaters
are provided with both automatic and manual reset
thermal cutouts to serve this function.
Airflow Interlocks – An airflow interlock must be
provided to keep the heater from operating with
extremely low or no airflow. HEATREX’s standard, a
built-in differential pressure airflow switch described
on page 15, senses static pressure in the duct as an
indicator of airflow. Separate wiring to the fan motor
or its controls is unnecessary.
Alternative methods for detecting airflow include:
1. T
 he fan relay, described on page 15, provides a
positive electrical interlock with the fan circuit.
2. A
 separate contactor, built into the duct heater,
can energize the fan when the duct heater is on.
3. A
 terminal block to allow field connection of
external contacts that close the circuit only when
the fan is operating.
Contactors – Contactors connected to the primary
thermal cutout and airflow interlock safety circuits
must be provided by the duct heater manufacturer.
Effective June 2009 UL requires that all open coil
element duct heaters be furnished with disconnecting
† Although UL requirements are uniform throughout the
country, local electrical codes may deviate from the NEC.
For information on local requirements, consult your
HEATREX representative.
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Specific Requirements
type controlling, safety and backup contactors
breaking all ungrounded conductors. Practically
speaking, this means that all, but small 120 and 277
volt single-phase open coil heaters, must be supplied
with either disconnecting contactors built into the
heater terminal box or into a remote panelboard.
HEATREX’s standard is to supply disconnecting
contactors which break all ungrounded conductors
in open coil heaters. Due to the intrinsic safety of
finned tubular duct heaters, UL does not require the
use of disconnecting type contactors. HEATREX’s
standard is to supply de-energizing contactors,
which break only one line of single-phase circuits
and two lines of three-phase circuits. Disconnecting
contactors are available with finned tubular heaters
if required.
Overcurrent Protection – For heaters drawing more
than 48 amps, the duct heater manufacturer must
provide some means of overcurrent protection either
built into the terminal box or a remote panelboard.
While fuses or circuit breakers are available to meet
this requirement, HEATREX’s standard is fuses.
Disconnecting Means – All duct heater installations
require a disconnecting means at or within sight of
the heater controls. We recommend that a built-in,
snap-acting, door interlocking disconnect switch
with marked “on” and “off” positions be specified on
all duct heaters. This insures the ultimate in safety,
since the heater and built-in controls cannot be
serviced without turning the disconnect switch off.
It is also far less expensive than one obtained and
installed in the field.
International Requirements
HEATREX heaters can be supplied to operate from
any electrical system throughout the world. Single
and three-phase voltages through 600 volts are
available. As described on pages 24 through 31, all
type HUA and HUP standard heaters are available
in 380, 400 or 415 volt, three-phase ratings. All
HEATREX heaters will operate on either 50 or 60
Hz.
 Installation Information
Standard Control Options

Heater Installation
Slip-in heaters slide through a rectangular opening
in the side of the duct per Figure 8. The heater is
designed for 1/4” (6.35 mm) clearance around the
inside of the duct. Slip-in construction is normally
preferred for ducts up to 4’ (122 cm) wide, but can
be furnished for any width. The heaters are held in
place with sheet metal screws through the back of
the terminal box into the duct. However, if the duct is
over 3’ (91 cm) wide, supporting rails in the bottom
of the duct are recommended.
Figure 8.
Flanged heaters are attached to matching external
duct flanges per Figure 9. The heaters are secured
by using either sheet metal screws or bolts and nuts
through the flanges.
A special flanged construction installed with
conventional HVAC slip-and-drive connectors is also
available. See page 37 for details.
Either flanged or slip-in heaters can be installed in
fiberglass ducts as illustrated in Figure 10. Note that
a sheet metal liner must be installed into the
fiberglass duct work, extending at least 6” (152 mm)
beyond the heater terminal box on both sides, more
Figure 9.
if required for structural rigidity.

Field Wiring Fiberglass Duct

Built-in power terminal blocks are sized for incoming
copper conductors with 75°C insulation, rated to
carry 125% of the heater load. However, lines may
be sized to carry 100% of the heater load if a) the Sheet Metal Liner
heater is rated at 50 KW or more, and b) the heater
is controlled by a cycling device, such as a multi-
staged thermostat, step controller, or SCR power
controller. Terminal blocks and knockouts on such
heaters will accommodate either 100% or 125%
conductors. See Table I for field conductor and
conduit sizing up to 500 MCM wiring. For higher
amperages, terminal blocks are furnished for two or
more parallel conductors per phase.
In general, aluminum conductors are not Sheet Metal Liner
recommended and terminal blocks are not sized for
aluminum. Consult your HEATREX representative if Fiberglass Duct
aluminum wire is specified for a particular job.

Figure 10.

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 Installation Information

Field control wiring should also be copper
conductors with 75°C insulation. Thermostat circuits
for SCR’s and step controllers are NEC Class II.
Many small heaters with 24 volt control circuits
are also NEC Class II. When Class II wiring is
permissible, it will be shown on the wiring schematic.
Other control circuits are NEC Class I.
When control power is taken from the heater’s load
circuit lines, HEATREX provides for the overcurrent
protection of all control circuits, as required by NEC
or UL. When control circuit power is obtained from
a separate source outside the heater, it is necessary
for the installer to provide overcurrent protection for
all control conductors.

Table I
Field Wiring and Conduit Sizing* for Incoming Conductors

KW in Voltages Shown Wire/ Trade
Conduit Size Load
Size
Single-Phase Three-Phase AWG or (Inches) Amps
120V 208V 240V 277V 208V 240V 480V MCM 1Ø 3Ø
1.4 2.4 2.8 3.3 4.3 4.9 9.9 14 1/2 1/2 12
1.9 3.3 3.8 4.4 5.7 6.6 13.3 12 1/2 1/2 16
2.8 4.9 5.7 6.6 8.6 9.9 19.9 10 1/2 3/4 24
4.8 10.8 9.6 11.0 14.4 16.6 33.2 8 3/4 1 40
6.2 10.8 12.4 14.4 18.7 21.6 43.2 6 1 1 52
8.1 14.1 16.3 18.8 24.4 28.2 56.5 4 1 11/4 68
9.6 16.6 19.2 22.1 28.8 33.2 66.5 3 1 11/4 80
Sized
For 11.0 19.1 22.0 25.4 33.1 38.2 76.4 2 11/4 11/4 92
125% 12.4 21.6 24.9 28.8 37.4 43.2 86.4 1 11/4 11/2 104
of 14.4 24.9 28.8 33.2 43.2 49.8 99.7 1/0 11/4 11/2 120
Heater
16.8 29.1 33.6 38.7 50.4 58.1 116.3 2/0 11/2 2 140
Load 19.2 33.2 38.4 44.3 57.6 66.5 133.0 3/0 11/2 2 160
22.0 38.2 44.1 50.9 66.2 76.4 152.9 4/0 2 2 184
24.4 42.4 48.9 56.5 73.4 84.8 169.6 250 2 21/2 204
27.4 47.4 54.7 63.2 82.1 94.7 189.5 300 2 21/2 228
29.8 51.6 59.5 68.7 89.3 103.0 206.1 350 21/2 3 248
32.2 55.7 64.3 74.2 96.5 111.4 222.8 400 21/2 3 268
36.5 63.2 73.0 84.2 109.5 126.3 252.7 500 21/2 3 304

54.0 6 1 1 65
70.7 4 1 1 85
83.1 3 1 11/4 100
95.6 2 11/4 11/4 115
Sized
54.0 108.1 1 11/4 11/2 130
For
54.0 62.4 124.7 1/0 11/4 11/2 150
100%
63.0 72.7 145.5 2/0 11/2 2 175
of
55.4 72.1 83.1 166.3 3/0 11/2 2 200
Heater

Load 55.2 63.7 82.9 95.6 191.2 4/0 2 2 230
53.0 61.2 70.6 91.9 106.0 212.0 250 2 21/2 255
59.2 68.4 78.9 102.6 118.4 236.9 300 2 21/2 285
64.5 74.4 85.9 111.7 128.9 257.7 350 21/2 3 310
69.7 80.4 92.8 120.7 139.2 278.5 400 21/2 3 335
79.0 91.2 105.3 136.9 158.0 315.9 500 21/2 3 380

*These tabulations are based on Table 310-16 of the NEC. Not more than 3 conductors in a raceway; 75°C rated copper wire.

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 Standard ControlOptions
Standard Control Options
Internal Wiring
Copper wire with a minimum of 105°C insulation is
used throughout. Connections are made with either
box lugs or connectors crimped on with calibrated
tooling. Terminal blocks are provided for all field
control and power wiring.
HEATREX developed the Control Option concept
to maintain compliance with changing UL and NEC
requirements and to stay current with new duct heater
temperature control systems. The concept has also
been broadened to include numerous “Special Features”
to meet a wide variety of special requirements.
Control Option G – Basic
Control Option G is a basic package designed
for normal comfort heating applications – i.e.,
those that do not require pneumatic control or the
unique features of SCR control. With Option G, the
temperature is controlled by a pilot duty thermostat
or a step controller.
Control Option G includes the following:
• Automatic and manual reset thermal cutouts to
protect against overheating. The automatic reset
cutout is wired into the control circuit; the manual
reset de-energizes the heater load.
• A differential pressure airflow switch to
de-energize the heater control circuit upon loss of
airflow.
• Magnetic contactors for each heater stage.
• Fuses to protect each circuit in any heater drawing
more than 48 amps.
• A control circuit transformer, with 24 or 120 volt
secondary as specified, including any overcurrent
protection required by UL or the NEC.
• A built-in, snap-acting disconnect switch with
door interlock to protect service personnel.
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Control Option J – Pneumatic
Control Option J is designed for pneumatic
temperature control.† The contractor need only
connect one air line and the main power lines to the
heater.
Option J includes the following:
• Automatic and manual reset thermal cutouts
and a differential pressure airflow switch. The
manual reset thermal cutouts always de-energize
the heater load. The automatic reset cutout and
airflow switch are normally wired in the control
circuit. However, when single-phase KW ratings
do not exceed the values in Table II, both of
these devices also carry the heater load directly,
eliminating the need for magnetic contactors.
• PE switches to control heater staging. To
minimize field labor, multiple PE switches are
factory-piped to a single port projecting through
the terminal box. All PE switches close on
pressure rise and open upon loss of pressure to
de-energize the heater.
• Magnetic contactors on all three-phase Option J
heaters and on single-phase heaters whose KW
ratings exceed those shown in Table II.
Table II
Open Coil Heaters
Single-Phase Voltage 120 208 240 277
Maximum KW 1.8 ­— — 4.1
Finned Tubular Heaters
Maximum KW 1.8 3.1 3.6 4.1
• Fuses to protect each circuit in any heater drawing
more than 48 amps.
• A transformer, with any overcurrent protection
required by UL or the NEC, to supply the internal
control circuit of heaters rated above 277 volts.
All other heaters have line voltage control circuits.
• A built-in, snap-acting disconnect switch with
door interlock to protect service personnel. 
†W
 here more than six stages of pneumatic control are required,
specify Option G with a step controller and pneumatic
transducer as Special Features. Such a heater will function in
the same manner as Option J with a maximum of 20 stages.
 Standard Control Options
Control Option K – Proportional
Control Option K is designed for the most precise
temperature control, using SCR proportional power
controllers and a matching electronic thermostat.
For heaters above the KW ratings in Table III, an
electronic step controller is also provided. It works
with the SCR to provide vernier proportional control.
For more details on this system, see page 21.
Table III
Voltage 120 208 240 277 480 600
Maximum 1 Phase 23.0 39.9 46.0 53.1 91.1 115.2
KW
3 Phase — 34.5 39.9 — 79.8 99.7
In addition to these electronic components, Control
Option K includes the following:
• Automatic and manual reset thermal cutouts
and a differential pressure airflow switch. The
manual reset thermal cutouts always de-energize
the heater load. The automatic cutout and airflow
switch are normally wired in the control circuit.
However, when single-phase KW ratings do not
exceed the values in Table IV, the automatic
reset cutout carries the heater load directly and
the airflow switch either carries the load directly
or is wired into the control circuit of the SCR,
eliminating the need for magnetic contactors.
• Safety magnetic contactors controlled by the
automatic reset cutout, for each heater circuit,
when the KW exceeds the ratings in Table IV.
Table IV
Open Coil Heaters
Single-Phase Voltage 120 208 240 277
Maximum KW 3.0 ­— — 6.0
Finned Tubular Heaters
Maximum KW 3.0 5.2 6.0 6.0
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• Magnetic contactors for each heater circuit.
• Fuses to protect each circuit in any heater drawing
more than 48 amps.
• A transformer, with any overcurrent protection
required by UL or the NEC, to supply the internal
control circuit of 24 or 120 volts per heater with
a step controller for vernier control and 24 volts
for all other heaters with SCR control. Wiring to
remotely mounted thermostats can be Class II
since thermostat circuits are low voltage limited
power circuits.
• A built-in, snap-acting disconnect switch with
door interlock to protect service personnel.
• A choice of room thermostat, page 12, Figure 15
or 16; duct thermostat, page 13, Figure 20 or 21;
built-in PE transducer, page 13, Figure 17; or field
inputs of 135 ohms, 2200 ohms, 0-10 VDC and
4-20mA are available.
Wiring Diagrams
Typical wiring diagrams for many of the commonly
used control options are located on pages 56 – 58.
These diagrams of open coil and finned tubular
heater constructions are intended to provide general
component arrangements and wiring information.
Specific wiring diagrams will be attached to the
inside of the enclosure doors for each heater and
remote panelboard and are available with certified
prints.
11
 StandardControl
Standard ControlOptions
Options
Thermostats
Room Thermostats
Single Stage, Catalog No. 1006998 Two or Three Stage, Catalog No. 1023723
• Non-digital, non-programmable, snap-acting • Digital, with programmable 5-1-1 day program or
bimetal, mercury free, SPST, with positive off 5-2 day program, mercury free
single stage • HEAT-OFF-COOL-AUTO EMERGENCY HEAT
• Range: 50° to 90°F (7° to 32°C) and fan AUTO-ON selections
• Accuracy: ±3°F (±1.5°C) • Easy to read backlit display
• Color: White • Range: 40° to 90°F (4.5° to 32°C)
• Inductive Rating: 1.2 amp at 30 volts max • Accuracy: ±1°F (±0.5°C)
• Offered with duct heater selection • Color: White
• Inductive Rating: Hardwire, three or four wire heat
Figure 11. only Class II circuit, 1.0 amp at 30 volts max

Single Stage, Catalog No. 1023721

• Digital, with programmable 5-1-1 day program or
5-2 day program, mercury free Figure 14.

• HEAT-OFF-COOL-AUTO and fan AUTO-ON

selections
• Easy to read backlit display Electronic Proportional, Catalog No. 1007101

• Range: 40° to 90°F (4.5° to 32°C) • Tamperproof construction

• Accuracy: ±1°F (±0.5°C) • Range: 40° to 90°F

• Color: White • Type: Ohmic – 2200 ohms

• Inductive Rating: Hardwire, two wire heat only • For use with HEATREX S95 step controllers
Class II circuit, 1.0 amp at 30 volts max
• Special Order

Figure 12. Figure 15.

Two Stage, Catalog No. 1007030

Electronic Thermostat, Catalog No. 1016941
• Digital, non-programmable, mercury free
• C1025 Thermostat is microcomputer-based,
• COOL-HEAT-OFF EMERGENCY HEAT and fan PI Control
AUTO-ON selections
• Range: 50° to 90°F
• Easy to read backlit display
• Type: Proportional 0-10 VDC
• Range: 40° to 90°F (4.5° to 32°C)
• For use with HEATREX SCR’s and S208 step
• Accuracy: ±1°F (±0.5°C) controllers
• Color: White
• Inductive Rating: Hardwire, three wire heat only
Class II circuit, 1.0 amp at 30 volts max

Figure 13. Figure 16.

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 Standard Control Options
Thermostats
PE Transducer Two Stage Light Duty, Catalog No. 1007044

Catalog No. 1020887 • Two single-pole, double throw switches

• Built into heater terminal box • Adjustable by screw on graduated cam dial
• PSIG range: 0 to 15 • Range: 55° to 85°F
• Throttling range: 1 – 12 psi • Differential: 2°F between stages
• Maximum pressure: 25 psi • Bulb Dimensions: 5/8” x 1111/16”
• Type: Ohmic – 135 ohms
• Capillary Length: 5’6”
• For use with HEATREX SCR’s and step controllers
• Resistive Rating per Heater Stage:
13.3 amps at 120 volts
6.6 amps at 277 volts

Figure 17. Figure 19.

Electronic Proportional
Catalog No.: Sensor, 1001083
Adjuster, 1001068
Duct Thermostats • Range: 60° to 120°F
Single Stage Heavy Duty, Catalog No. 1023953 • Type: Ohmic – 2200 ohms
• Liquid filled sensing element with snap-acting • For use with HEATREX S95 step controllers
contacts
• Range: -30° to 100°F
• Differential: 3 to 12°F between stages
• Bulb Dimensions: ⅜” x 4”
• Capillary Length: 8’
• Resistive Rating: 22 amps, 120 to 277 volts Figure 20.

Electronic Thermostat
Catalog No.: Sensor, 1016942
Adjuster, 1016941
• Range: 50° to 90°F
• Type: PI Proportional 0-10 VDC
• For use with HEATREX SCR’s and S208 step
controller

Figure 18.

Figure 21.

13

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 Construction
Standard Control Options
Electrical
HEATREX offers a broad range of electrical components The secondary manual reset thermal cutout
for temperature, safety, and power control. (Figure 23) has a temperature setting approximately
50°F (10°C) higher than the automatic reset cutout
For most applications, the Control Option system,
to provide protection only if the primary system fails.
described in the previous section, makes it easy to
Once it has tripped, it is necessary to press a reset
specify a complete control package.
tab to return the heater to operation.
For applications requiring a special control system,
the following section describes components, their
applications, and limitations.

Bi-Metallic Thermal Cutouts

Both UL and NEC require thermal cutout protection
against overheating due to insufficient airflow, air
blockage or air failure. Two levels of protection are
provided:
Figure 22.
The primary or automatic reset thermal cutout
(Figure 22) is a fixed temperature, bi-metallic
disc type device which opens when its set point
is reached and automatically resets when the
temperature falls below its set point. The operating
disc and contacts are completely enclosed to
prevent infiltration of dirt or physical damage. This
single pole device is most often wired into the heater
control circuit, but will carry single-phase loads up to
25 amps at 240 volts and 22 amps at 277 volts (See
Table V). Most heaters have only one automatic
reset thermal cutout. However, on large heaters, two
or more may be supplied, wired in series.
Figure 23.
Open coil heaters use a cutout rated to carry the
maximum heater circuit load allowed by UL and
NEC: 48 amps at 480 volts. One cutout is supplied
for each heater circuit, or group of circuits, drawing
48 amps or less.
Many manufacturers use heat limiters or fusible
links which require field replacement when an
overtemperature condition occurs. This often involves
removing the heater from the duct and always
involves ordering replacement heat limiters from the
manufacturer. With HEATREX’s manual resets, the
heater can immediately be put back into operation,
simply by pressing the reset button.
There is no danger that backup protection will be lost
because replacement heat limiters are not available.
Furthermore, the services of a qualified electrician
are not required, since maintenance personnel can
easily reset the manual cutouts.
Linear Thermal Cutouts

Table V

Single-Phase Voltage 120 208 240 277

Maximum KW 3.0 5.2 6.0 6.0
Figure 24.

The linear thermal cutouts (both automatic and

manual reset) sensing element (Figure 24) is a fluid-
filled capillary tube, strung across the entire heater

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width. If any 6” (152 mm) segment of the capillary
is overheated, the cutout will de-energize the entire
heater, providing additional protection if the airflow
is not sufficiently uniform. Furthermore, it is fail safe
– it will trip if the capillary loses its fill. These cutouts
are normally provided for pilot duty but can carry the
heater load directly up to 25 amps, 277 volts, single-
phase.
Custom open coil heaters – Only one linear
automatic and/or one linear manual, set 50°F (10°C)
higher than the automatic, may be furnished, in
addition to the standard cutouts. They are wired in
series with the standard disc type automatic cutout.
Finned tubular heaters – Triple overheating
protection is standard for finned tubular heaters.
In addition to the automatic disc thermal cutout,
Figure 22, both automatic and manual reset linear
cutouts, Figure 24, are furnished.
An automatic primary linear limit cutout, strung
across the top and leaving air face of the coil
(Figure 25), protects against overheating caused
by low airflow. This device will turn the heater off
if the fixed temperature set point is exceeded. It
automatically resets when the temperature drops to
safe levels.
Figure 25.
A manual secondary linear limit cutout protects
against failure of the primary overtemperature
system. With a fixed temperature setting higher than
either of the primary cutouts described above, this
device is designed to trip only if both of the primary
cutouts stick in the closed position, or controlling
contactor points weld together.
www.heatrex.com
Construction
Electrical
Airflow Switch
Figure 26.
A diaphragm operated differential pressure switch
(Figure 26) is normally used to prevent a heater from
operating unless air is flowing. The switch is provided
with a velocity pick-up tube extending into the duct
area, making it sensitive to static pressure as well as
velocity pressure.
The switch requires at least .07” (17.4 Pa) of water
column pressure difference between the inside and
the outside of the duct. If the pressure is below
.07”, a fan relay should be substituted as described
below.
Airflow switches are normally connected for positive
pressure – i.e. for a heater located on the discharge
side of a fan. If the heater is on the suction side, the
switch may be specified or field converted for negative
pressure. In most applications the airflow switch is
wired into the heater control circuit, but it can carry
the heater load directly up to 15 amps at 277 volts,
single-phase.
Fan Relay
Figure 27.
A fan relay is available as an alternate to the
standard airflow switch. It has the advantage of
being a positive electrical interlock between the fan
and the heater (see Figure 27 for wiring details).
Its primary disadvantages are that it requires field
wiring back to the fan control circuit and does not
protect against conditions such as belt failure. When
a fan relay is required, specify the fan starter control
voltage. If not specified, it will be assumed to be the
same as the heater control voltage. Both a fan relay
and an airflow switch can be furnished.
15
 Construction
Standard Control Options
Electrical
Magnetic Contactors Control Transformer

Figure 30.
Figure 28.

All magnetic contactors supplied by HEATREX are
UL recognized for limit control duty, as opposed to
less severe, general purpose duty. De-energizing
contactors, break one power line on single-phase
circuits and two lines on three-phase. Disconnecting
contactors, break all ungrounded conductors, one
power line on 120 and 277 volt single-phase, two
power lines on 208 and 240 volt single-phase and
all lines on three-phase. Both de-energizing and
disconnecting contactors are available with ratings
up to 600 volts. Contactors are available with holding
coil voltages of 24, 120, 208, 240 or 277.
Built-in control transformers are available to supply
either 24 or 120 volt control circuits. The transformer
primary is factory connected to the main supply and
the secondary is wired directly to the built-in control
components. Overcurrent protection and secondary
grounding are provided when required by UL and
the NEC.
Disconnect Switch

Fuses

Figure 31.

Built-in disconnect switches are an inexpensive,

Figure 29.
Low resistance fuses are mounted in phenolic fuse
blocks fitted with extra tension springs to assure
cool connections. To protect against faults in both
contactors and heating elements, fuses are located
on the line side of contactors built into heaters. To
meet NEC requirements for continuous loads, fuses
are rated at least 25% above the load they are
protecting.
positive way to meet the NEC requirement for a
disconnecting means within sight of the heater,
controller(s), and overcurrent protection devices.
The switches are interlocked with the heater terminal
box cover and have labeled “on” and “off” positions.
If there are any external sources of control voltage,
a separate toggle switch is provided. Together these
devices result in a “dead front” design to protect
service personnel. Both fused (up to 48 amps) and
unfused switches are available. However, unfused
switches are most often specified, as they meet code
safety requirements.

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Pilot Lights
Figure 32.
Pilot lights, projecting through the side of the heater
terminal box, indicate functional operation. The most
commonly specified functions are:
Heater On – This indicates that power has been
supplied to the heater, but does not necessarily
indicate that the control system is calling for heat or
that heat is being produced.
Low Airflow – This indicates that there is either
no airflow, or it is so low that the airflow switch has
prevented the heater from operating.
Each Stage On – These indicate when each heater
stage has been energized. Not available with SCR
controlled stages.
Overtemperature – This indicates when the
automatic reset thermal cutout has tripped due to
an overtemperature condition. Only available with
custom heaters.
www.heatrex.com
Construction
Electrical
Pilot Switch
A pilot switch is a simple means of de-energizing the
heater between seasons or during prolonged shut-
downs. The switch is wired in series with contactor
holding coils. It cannot be used as a disconnecting
means and is therefore labeled with “on” and
“standby” positions. If disconnecting contactors are
also specified, the switch will have a labeled “off”
position in accordance with UL and NEC provisions.
Pneumatic/Electric (PE) Switches
Figure 33.
Built-in and pre-wired PE switches are available
for pneumatic control systems. To minimize field
labor, all PE switches are factory piped to a single
port projecting through the terminal box. Pneumatic
connections may, therefore, be made without
interfering with electrical connections. Standard
switches close on pressure rise, resulting in a fail-
safe system since a loss of pressure de-energizes
the heater. “Open on rise” switches are available on
custom heaters for special applications.
PE switches can either be used as pilot duty
devices, or to carry heater loads up to 22 amps, 480
volts, single-phase.
PE switches are limited to six stages, because it is
difficult to calibrate more switches and still maintain
proper staging. For more than six stages, specify a
step controller (described on pages 19 and 20) with
a pneumatic transducer (described on page 13).
17
 Construction
Standard Control Options
Electrical
Electronic Controls SCR Power Controllers
HEATREX’s controls division is the recognized
industry leader in designing and manufacturing
electronic controls for electric heating equipment.
Controllers manufactured by HEATREX are precise
and compatible with the latest HVAC control
systems.
HEATREX duct heaters may be specified with SCR
power controllers or electronic step controllers. While
these devices are inherently different, they have
certain common characteristics:
• Input Flexibility – Normally supplied with a
thermostat, controls can be used with many field-
supplied ohmic sensors or electronically generated
Figure 34. A & B Series for indoor use
control signals, such as proportional milliamp
or DC voltages. Thus they are compatible with
virtually any field-installed control system.
• Low Voltage Control – NEC Class II field wiring
may be used on the thermostat circuits of all
controls.
• High Ambient Temperature Rating – All units
are designed for full load operation in high ambient
temperatures, making them particularly suitable
for use in duct heater terminal boxes and remote Figure 35. Series 103 for outdoor and dusty applicatons
control panels.
The advanced programming and circuitry of the A&B
• Fail Safe Circuitry – In the event of either a short
Series and the Series 103 SCR’s provides multi-
or open circuit in the thermostat leads, all controls
purpose operation and field-switchable temperature
de-energize the heaters, protecting the heaters
control inputs for 4-20 milliamps, 0-10 VDC, 135
from runaway overheating conditions.
ohms, and 2200 ohms. Custom inputs are available.
• LED Function Indicator – Light emitting diodes Please consult the factory.
(LED pilot lights) indicate the operating status
SCR power controllers modulate the entire heater
of the controls. On SCR power controllers, the
load, varying the heater output from 0 to 100%
LED shows when the heater is on, indicating the
of the total heater KW. Working on a one second
percentage output being provided to the heater.
time base, the heater will be energized only for the
On step controllers, LED’s show when control
number of AC cycles necessary to produce the exact
power is on and the status of each heater stage.
amount of heat required. The resulting precision
• Continuous Feedback – Logic and control circuits control and rapid response make the HEATREX
continuously monitor the input signal to determine SCR the choice for many heating applications. For
if more or less heat is required. Appropriate action example, multi-stage discharge temperature control
is then taken automatically. of a heater can produce unacceptable temperature
swings, resulting in poor comfort levels and
inefficient energy use. The same heater controlled
by an SCR and a sensitive duct thermostat will
produce stable, even heat for maximum comfort and
efficiency.

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The SCR’s power switching devices are mounted
on a large finned heat sink which extends outside
the heater terminal box or control panel. The
conservative SCR rating (no more than 75% of the
manufacturer’s rating) and this generous heat sink
insures against overheating and SCR failure.
Both single-phase and three-phase SCR’s are
available as are master and slave units. Each master
is capable of driving up to three slaves, giving a
capability for 100%, fully proportional SCR control.
However, when the load exceeds that tabulated
in Table III on page 11, it is more economical to
combine SCR’s with an HEATREX step controller in
a vernier configuration. See page 21.
The SCR is switched on only as the voltage
wave form crosses the zero point, which virtually
eliminates radio frequency interference (RFI). All
480 and 600 volt SCR’s have a 1200 peak inverse
voltage (PIV) rating and transient absorbers that
protect them from the high voltage spikes found on
480 and 600 volt lines.
Except on small, single-phase heaters where the
heater load can be carried directly by the automatic
thermal cutout (see Table V, page 14), all heaters
with SCR’s require safety contactors for operation of
the primary overtemperature protection system.
www.heatrex.com
Construction
Electrical
Step Controllers (Sequencers)
Figure 36. Electronic Sequencers
HEATREX S95 step controllers can handle simple
multi-stage control to sophisticated vernier systems.
The advanced programming and circuitry of the S95
provides multi-purpose operation and field-switchable
temperature control inputs for 4-20 milliamps, 0-10
VDC, 135 ohms, and 2200 ohms. Custom inputs are
available. Please consult the factory.
In addition to those previously listed features, S95
step controllers have the following important
advantages:
• They de-energize and recycle all stages, upon
momentary power interruption, to avoid heavy line
surges and to provide a soft start when power is
restored.
• Adjustable time delay of 5 seconds to 10 minutes
between stages can be field programmed. For
span settings for each input, see Table VI on page
21.
• Both master and slave units are available, with 10
stages of operation. Up to 20 stages may be
controlled with master slave combinations. Each
S95 step controller is factory programmed for the
exact number of stages required.
• The number of stages energized with a
proportional S95 step controller is directly
proportional to the input signal (normally DC volts
or milliamps). Proportional step controllers are
used with many building management systems.
19
 Construction
Electrical
Step Controllers (Microprocessor-based)
Figure 37. Microprocessor-based S208
HEATREX’s microprocess-based S208 step con-
troller provides temperature control for staged and
vernier systems up to 4 stages. The S208 has many
of the same advanced features as the S95 step con-
troller but is designed for use with smaller heaters.
The S208 includes the following features:
• Up to four stage control.
• Vernier control for heaters up to 240 amps.
• Field-switchable temperature control inputs for
4-20 milliamps and 0-10 VDC.
• Class II - designed to be used in low Class II
24 volt circuits.
• Time delay, the rate the stages are turned ON
or shut OFF, is determined by a field adjustable
1-75 second time delay.
• Proportional control, the number of stages turned
ON, is proportional to the input signal.
20
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While standard HEATREX SCR’s and step control-
lers satify the majority of HVAC applications, a much
broader range of special capabilities is also available
with HEATREX custom heaters.
• Close Tolerance Controller - When used with a
properly designed system, this modified SCR is
capable of maintaining tight temperature control
in a controlled space, such as clean rooms and
calibration labs.
• Fan Motor Controls - In additional to control
of the heater, it is often desirable to control and
power the fan through the heater. The heater
is designed so that the electrician brings only
one power circuit into the terminal box which is
subdivided for fan power. The motor controller,
overloads and overcurrent protection for this aux-
iliary fan circuit and motor will be provided.
• Low Limit Discharge Control - A thermostat is
placed in the occupied area which has primary
control of the heater. A second thermostat is
placed in the discharge duct which is set for a
predetermined minimum discharge temperature
and will override the room thermostat, if the
discharge temperature falls below the duct sen-
sor set point. This prevents cold air from being
discharged into the occupied area.
• Temperature Averaging - Multiple sensors, with
a single set point, are placed in different zones
or in several locations of a large area, such as a
warehouse. The controller averages the read-
ings of all the sensors to determine the heater
output. This design can be used in the hot deck
of multizone units.

Vernier Proportional Control
Recommended for large KW heaters, the economical
vernier control system offers many of the advantages
of full SCR control. One vernier heater stage is
connected to a slave SCR controller. Additional
stages are sequenced on and off while the SCR-
vernier stage automatically fills the gap between the
step controlled stages, providing full proportional
control over the entire heater KW range. Both the
slave SCR-vernier stage and the step-controlled
stages are controlled by the step controller. The
vernier system is normally recommended for heaters
drawing more than 96 amps for three-phase or 192
amps for single-phase (see Table III, Page 11).
For proportional vernier control systems used
with building management systems, HEATREX
recommends that the SCR stage be sized the same
KW as the non-SCR stages to obtain the optimum
control. See Figure 38.
Construction
Electrical
Thermostats/Inputs for Electronic
Controls
An electronic proportional room thermostat (page 12,
Figure 15) is standard for the A&B Series Power
Controllers and the S208 Step Controllers. A duct
type thermostat can be specified as well (page 13,
Figure 21). A tamperproof electronic proportional
room thermostat is standard for the S95 Series
Step Controllers (page 12, Figure 15). A duct type
thermostat is also available (page 13, Figure 20).
When a special thermostat or field-installed control is
used, the controller can be specified with any of the
inputs listed in Table VI.
Table VI
Typical thermostat inputs available for step
controllers & SCR’s
Spans (Factory Set)
Inputs
SCR’s S95 Step Controller
2200 ohms 100 ohms 100-400 ohms (adjustable)
135 ohms 100 ohms 120 ohms
4-20 mA* 12.8 mA 15 mA
0-10 VDC 8.0 VDC 9 VDC

*S
 tandard input impedance is 250 ohms
All inputs listed are available with HUA and HUP type heaters.
These inputs plus a variety of other inputs are available with
custom heaters.

Proportional vernier control DEAd BAND VERNIER CONTROL WITH

with 9 step controlled stages 2200 OHM INPUT AND 200 OHM SPAN
and one SCR stage for 0-10 VDC (DEADBAND) SETTING
input

TOTAL LOAD
0% OF SCR STAGE "ON"

100

90 100
80
% POWER REQUIRED

70
75 SCR STAGE
SCR CONTROLLED
60
LOAD
50

40 50

30
STEP STEP
20 CONTROLLED CONTROLLED
STAGES ARE 25 STAGES ARE
10 TURNED "OFF" TURNED "ON"

0
1 2 3 4 5 6 7 8 9 9+ SCR STAGES ON
2000 2050 2100 2150 2200 2250 2300 2350 2400
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 VDC INPUT

Figure 38. Figure 39.

21

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 Construction
Mechanical
Slip-In Heaters
Figure 40.
Slip-in heaters are designed so that the entire frame,
except the terminal box, slips into the duct with 1/4”
(6.35mm) clearance all around. It is installed, as
shown in Figure 8 on page 8, through a rectangular
opening in the side of the duct and held in place with
sheet metal screws through the back of the terminal
box, which is large enough to provide a seal with
the duct. Figure 40 illustrates the construction and
provides reference dimensions.
Slip-in construction is used because it allows duct
work to be installed before the heaters are available,
simplifies on-the-job changes in heater location,
and is easily retrofitted into existing duct systems.
Furthermore, small slip-in heaters may be installed
without any special provisions for their support.
While custom slip-in heaters can be provided to fit
specific duct dimensions (W x H), selecting standard
open coil type HUA heaters maximizes economy and
minimizes delivery times.
22
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Flanged Heaters
Figure 41.
Flanged construction is available with inside face
dimensions exactly matching the duct dimensions.
The heater frame is attached to matching turned
out duct flanges as illustrated in Figure 9 on page
8. Standard flanges are a minimum of 3/4” deep;
deeper flanges are provided on larger heaters for
structural reasons. Custom flanges can be provided
upon request. Figure 41 illustrates flanged heater
construction and provides reference dimensions.
Standard HUP flanged heaters are available to meet
many of the commonly used duct sizes. Listings of
the available sizes are shown on page 25. Full range
of control options and construction features are
offered.
Zero Clearance Construction
Slip-in and flanged heaters are UL Listed for zero
spacing between the duct and combustible material
to be placed directly against surrounding duct work.
Although this construction is not required by UL on
heaters above 50 KW, HEATREX supplies it on
all heaters regardless of KW. However, incorrect
mounting will void the UL Listing, and may make the
installation unsafe.
 Construction
Mechanical
Physical Standards
Heater Frame and Terminal Box
Frames and terminal boxes are fabricated from
heavy gauge corrosion resistant steel. Optional
stainless steel frames are recommended for wet
or corrosive applications. Standard NEMA 1 type
terminal boxes have hinged covers.
Knockouts are provided for all field connections.
Open coil heater element support brackets are
spaced on 4.5” (114 mm) maximum centers to avoid
coil sag, even under the most extreme operating
conditions. Strengthening ribs on the brackets insure
that coils are held in their proper location, even on
Figure 42. large heaters.
Finned tubular heater element support brackets are
spaced on 36” (914 mm) maximum centers.

Figure 43.

Standardized dimensions and terminology avoid

errors and confusion. The most common dimensions
are defined in Figures 40 and 41.
Figures 42 and 43 illustrate airflow terminology.
Most HEATREX open coil type heaters are suitable
for horizontal or vertical airflow, but for finned tubular
type heaters or heaters with pressure plates, exact
airflow direction (right, left, up or down) must be
specified.
In most heaters, the terminal box is significantly
larger than the heater frame, in at least one
direction. This is referred to as the terminal box
overhang, defined in Figures 42 and 43. For
horizontal airflow, left overhang is standard. For
vertical airflow, up overhang is standard. Optional
right and down overhangs are also available.

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 Standard Duct Heaters
Open Coil
HUA Slip-In and HUP Flanged Heaters The 80% Rule – HEATREX recommends the heater
should occupy at least 80% of the actual inside area
of the duct, as shown in Figure 45. Only small
amounts of air will bypass the heater around its
perimeter and normal turbulence will rapidly mix this
unheated air with heated air downstream.

Figure 44.

HEATREX has developed HUA (Figure 44) and HUP

(Figure 46) heater lines to satisfy most typical space
heating requirements, simplifying specification,
ordering and delivery.
Both standard and quick ship delivery programs are Figure 45.
available for the full line of HUA and HUP heaters.
All HUA heaters may be installed in ducts with up to
1” of interior lining, but the heater must be selected
KW Ratings to fit the inside duct dimensions. For example, to fit a
HUA and HUP heaters are available up to 456 KW. duct with 36” x 16” outside dimensions, but with 1” of
The KW ratings are limited both by frame size interior insulation, specify a 35” x 14” heater.
and electrical characteristics. Heater availability
HUP flanged open coil heater frame sizes range
can be determined by contacting an HEATREX
from the smallest at 8” wide by 6” high to the largest
representative, who can provide a computerized
at 48” wide by 38” high or 72” wide by 28” high or
heater selection with exact heater dimensions in
any duct size in between these sizes (i.e. 35.75”
minutes.
by 27.75”). HUP cannot be used with interior lines
Frame Sizes ducts. If you require a frame size not offered by the
HUP then HEATREX can manufacture a custom
The use of a standard open coil HUA slip-in heater frame size to meet virtually any application.
will both reduce cost and permit rapid shipment.
HUA frame sizes range from the smallest at 8”
wide by 6” high to the largest 48” wide by 40”
high or 72” wide by 30” high. The HUA offering
has been opened up to allow for any duct size in
between these sizes and includes fractional widths
and heights dimensions (i.e. 24.625” by 17.25”).
HEATREX can manufacture a custom slip-in frame
size if your requirements exceed the HUA offering.

Figure 46.

24

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 Standard Duct Heaters
Open Coil
Table VII
Commonly used duct widths and heights are shown in the charts below, in-between widths and heights are
also available as standard HUA (slip-in) and HUP (flanged) duct heaters.
Sizes and Maximum KW Ratings
Duct Height Type HUA
6” 8” 10” 12” 14” 16” 18” 20” 24” 30” 36” 40”
Slip-in heater
8” 6 9 12 16 19 22 25 28 35 45 54 61
10” 8 12 16 20 24 28 33 37 45 57 70 78 Maximum KW ratings
12” 10 15 20 25 30 35 40 45 55 70 85 96
in available frame sizes
14” 11 17 23 29 35 41 47 53 65 83 101 113
shown at left.
16” 13 20 27 34 41 48 55 62 75 96 117 131
18” 15 23 31 39 46 54 62 70 85 109 132 148
20” 17 26 34 43 52 61 69 78 96 122 148 165
22” 19 28 38 48 57 67 77 86 106 135 164 183
24” 21 31 42 52 63 74 84 95 116 148 179 200
26” 22 34 45 57 68 80 91 103 126 160 195 218
28” 24 37 49 62 74 86 99 111 136 173 211 235
Duct Width

30” 26 39 53 66 79 93 106 119 146 186 226 253

32” 28 42 57 71 85 99 114 128 156 199 242 270
34” 30 45 60 75 91 106 121 136 166 212 257 288
36” 32 48 64 80 96 112 128 144 176 225 273 305 Figure 47.
38” 34 51 68 85 102 119 136 153 187 238 289 323
40” 35 53 71 89 107 125 143 161 197 251 304 340 Installation of
42” 37 56 75 94 113 131 150 169 207 263 320 358 Slip-in heater
44” 39 59 79 98 118 138 158 177 217 276 336 375
48” 43 64 86 108 129 151 172 194 237 302 367 410
54” 48 73 97 121 146 170 194 219 268 341 — —
60” 54 81 108 135 162 189 216 244 298 379 — —
66” 59 89 119 149 179 209 239 268 328 418 — —
72” 65 97 130 163 195 228 261 293 359 456 — —

Duct Height Type HUP

6” 8” 10” 12” 14” 16” 18” 22” 28” 30” 34” 38” Flanged heater
8” 11 14 18 22 25 29 33 40 51 55 62 69
10” 13 18 22 27 32 36 41 50 64 68 78 87
Maximum KW ratings
12” 16 22 27 33 38 44 49 60 77 82 93 104 in available frame sizes
14” 19 25 32 38 45 51 57 70 90 96 109 122 shown at left.
16” 22 29 36 44 51 58 66 80 102 110 125 139
18” 24 33 41 49 57 66 74 91 115 124 140 157
20” 27 36 45 55 64 73 82 101 128 137 156 174
22” 30 40 50 60 70 80 91 111 141 151 171 192
24” 33 44 55 66 77 88 99 121 154 165 187 209
26” 35 47 59 71 83 95 107 131 167 179 203 227
28” 38 51 64 77 90 102 115 141 180 193 218 244
Duct Width

30” 41 55 68 82 96 110 124 151 193 206 234 262

32” 44 58 73 88 102 117 132 161 205 220 250 279
34” 46 62 78 93 109 125 140 171 218 234 265 296 Figure 48.
36” 49 66 82 99 115 132 148 182 231 248 281 314
38” 52 69 87 104 122 139 157 192 244 262 296 331 Installation of
40” 55 73 91 110 128 147 165 202 257 275 312 349 Flanged heater
42” 57 77 96 115 135 154 173 212 270 289 328 366
44” 60 80 101 121 141 161 182 222 283 303 343 384
48” 66 88 110 132 154 176 198 242 308 331 375 419
54” 74 99 124 148 173 198 223 273 347 — — —
60” 82 110 137 165 193 220 248 303 386 — — —
66” 91 121 151 182 212 242 273 333 424 — — — 25
72” 99 132 165 198 231 264 297 364 463 — — —
Note: Maximum kW ratings may vary based on voltage and phase combination.
 Standard Duct Heaters
Open Coil
Detail Dimensions
The wide variety of HUA and HUP (Figures 47
and 48) heaters makes it impractical to list the exact
heater dimensions for every possible heater. For
dimensional details, contact your local HEATREX
representative.
Voltage and Phase
Heaters are available in the voltage and phase
combinations shown below. All are for operation at
50 or 60 Hz.
When three-phase is specified, each heating stage
will be furnished with a multiple of three elements to
give a balanced three-phase load.
Control Circuit Options & Special
Features
HUA and HUP heaters are available with Control
Options G, J and K and a full range of Special
Features. These are described briefly in Table VIII
and in more detail in the standard Control Options
section of this catalog, pages 10 and 11.
Number of Heating Stages
Single and three-phase HUA and HUP heaters are
available with multiple heating stages. To comply
with our UL and NEC maximum circuit sizes, no
stage is rated at more than 48 amps.

Voltage 120 208 240 277 208 240 380 400 415 480 600

Phase 1 3

Table VIII
Control Options

Control Disconnect Thermal Airflow Control PE

Contactors Fuses SCR Thermostat
Option Switch Cutouts Switch Transformer Switches
G 1
     
Basic
J 2 3 1
      
Pneumatic
K 2 1 4
       
Proportional
Notes: 1. Fuses supplied only on heaters over 48 amps.
2. Contactors supplied only when other devices cannot carry heater load.
3. Transformer only supplied on heaters rated higher than 277 volts.
4. Choice of room or duct thermostat, 135 ohms, 2200 ohms, 0-10 VDC or 4-20 mA inputs.
See pages 12 and 13 for full description of thermostats.

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 Standard Duct Heaters
Open Coil
Special Features
While HUA slip-in and HUP flanged heaters may HUA/HUP heaters both mechanically and electrically.
be specified with one of the standard control circuit These are listed in Table IX with a brief description,
options, individual job requirements may demand availability, and notes on any limitations of their use.
slight variations from the standards. The most
Table X provides a summary of thermostats offered
common variations are covered by HEATREX’s set
with HEATREX HUA/HUP heaters. See pages 12
of Special Features which may be used to modify
and 13 for more detailed descriptions.

Table IX

Special
Page Availability
Special Features Feature Description
Ref. & Limitations
Code

Mechanical

Allows heater to be used in applica-

Horizontal Airflow U8 tions where airflow is either right 23 Available on all heaters.
(U4) or left (U6)

Allows heater to be used in applica-

Vertical Airflow U9 tions where airflow is either vertical 23 Available on all heaters.
up (U3) or vertical down (U5.)

40% open perforated plate installed Available on all heaters.

onto the inlet side of the heater Exact airflow direction must
Pressure Plate V1 35
frame to help even out irregular be specified U3, U4, U5 or
airflow patterns. U6.

Wire mesh screen for attachment to Available on all heaters.

Protective Screen V/V2 the heater frame. Can be furnished 36 Screens are shipped loose
for one or both sides. for field installation.

Stainless Steel Frame and Heater frame and terminal box con-
H2   Available on all heaters.
Terminal Box structed of 304 stainless steel.

Aluminized Steel Frame Heater frame and terminal box con-

H1   Available on all heaters.
and Terminal Box structed of aluminized steel.

Used in ducts lined with more than

Insulated Duct Construc-
GG2
tion for Slip-in Heaters
1” thick interior insulation. Inside
Available with HUA heaters
duct dimensions and insulation 36
only.
thickness must be specified. Maxi-
mum 6” thick lining.

Extended terminal pins to provide

an unheated section adjacent to
Unheated Sections G2 36 Available on all heaters.
the heater terminal box. Maximum
extended terminal pin length of 6”.

Substitute Negative Allows heater to be used on inlet

Q5/Q6 15 Available on all heaters.
Pressure Switch side of fan.

27

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 Standard Duct Heaters
Open Coil
Table IX (continued)

Special
Page Availability
Special Features Feature Description
Ref. & Limitations
Code

Mechanical (cont.)

Heater will be supplied with terminal

Right/Down Terminal box overhang on right (if horizontal
L4/L5 23 Available on all heaters.
Box Overhang airflow installation) or downward (if
vertical airflow installation).

Prevents condensation inside termi-

nal box when heater is installed in
Insulated Terminal Box B2 35 Available on all heaters.
air conditioning duct running through
un-airconditioned area.
Allows installation in dusty areas
and satisfies local codes requiring
Dust-Tight Terminal Box B7 34 Available on all heaters.
dust-tight box, if installed in area
used as return air plenum.
All controls except thermal cutouts,
Available on all heaters ex-
airflow switch and pilot switch will
Remote Panelboard B5 37 cept when transformer and
be supplied in a separate NEMA 1
contactors are deleted.
panelboard.
Electrical

Add “Stage On” To indicate when each heating stage Available on all heaters ex-
P1 17
Pilot Light(s) is producing heat. cept Option K SCR stages.
Separate pilot lights to indicate that Available on all heaters.
Add “Low Airflow” power has been supplied to the When fan relay has been
and “Heater On” P2, P3 heater, that it is ready for operation, 17 substituted for airflow
Pilot Lights and whether airflow has been inter- switch, only “Heater On”
rupted. will be supplied.
When static pressure in the duct is
Available on Option G & K
too low (below .07” WC) to operate
heaters except Option G
the airflow switch or when airflow
Fan Relay N(000) 15 heaters where deletion of
switch is not desired. (000) denotes
contactors and transform-
holding coil 24, 120, 208, 240, or
ers is specified.
277 volts.
Allows better temperature control of
Add HEATREX Only available on Option
high capacity heater by using mul-
Electronic S 19-20 G heaters with 2 or more
tiple stages controlled by electronic
Step Controller heating stages.
thermostat and step controller.
To meet specifications which call for
Low Watt Density Coils D3, D4   Available on all heaters.
low watt density coils.
Available on Option K heat-
Add Built-in PE ers or Option G heaters
E32, S19 To allow for pneumatic control. 13
Transducer with step controller and 5 or
more stages.
Transformer Primary Available with all heaters
T1 Add transformer primary fusing.  
Fusing with built-in transformer.

28

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 Standard Duct Heaters
Open Coil
Table IX (continued)

Special
Page Availability
Special Features Feature Description
Ref. & Limitations
Code

Electrical (cont.)

Allows control circuit to be obtained Only available on Option G

Delete Transformer  
Delete Transformer
 
& Contactors
from source outside the heater or,
when line voltage is equal to control
voltage, directly from power lines
within the heater.
Allows for control of heater directly
using load carrying thermostats.
heaters. Must be specified
16 if control voltage is not 120
or 24 volts. Customer must
specify control volts.
Available only on single
stage, single-phase, Option
G heaters with KW not
16 exceeding the following.
Voltage 120 277
Max. KW 1.8 4.1

External fused and grounded trans-

Transformer
T3 former secondary for Class II 24 volt   Available on all heaters.
Secondary Fusing
control circuits.

Heater control circuit transformer Available on all heaters.

Additional User
sized for additional user VA. A Consult factory for 1 week
Control Circuit  ­  
control terminal block is furnished for or 72 hour heater avail-
Voltage
field connection. ability.

Allows for use of field installed dis-

Delete Disconnect   connecting means. (Must be within 16 Available on all heaters.
sight of the heater.)

Door interlocking disconnect with

Fused Disconnect
Q1 line fusing for heaters loads up to 48 16 Available on all heaters.
Switch
amps or less.
Automatic reset linear limit thermal
Available on all heaters.
Linear Limit cutout wired in series with the disc
Exact airflow direction must
Automatic Reset Z/Z1 type automatic reset to provide 14
be specified U3, U4, U5 or
Thermal Cutout redundant primary over temperature
U6.
protection.
Available on all heaters
whose KW is lower than
or equal to the following.
(Other heaters include fus-
ing as standard):
Allows for addition of one set of
Add Fuses for Heaters fuses to low amperage heaters that Line KW (at 48 amps)
F1 16 Volts 1 Phase 3 Phase
Rated 48 Amps or Less do not need internal fusing to meet
UL and NEC requirements 120 5.7 -
208 9.9 17.2
240 11.5 19.9
277 13.2 -
480 23.0 39.9

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 Standard Duct Heaters
Open Coil
Table X
Summary of Thermostats available with Option G or K Heaters (No Thermostats are supplied on Option J
Heaters)

Used
with Catalog
Type of Thermostat Comments
Control Number
Option

Rated for 30 volts max. Offered

1 Stage G 1006998 (Fig.11)
with Duct Heater Selection

Digital Display, Rated for 30

1 Stage G 1023721 (Fig. 12)
volts max. Special Ordered
Pilot
Duty
Digital Display, Rated for 30
2 Stage G 1007030 (Fig. 13)
volts max.
ROOM

2 or 3 Programmable with Digital

G 1023723 (Fig. 14)
Stage Display, Rated for 30 volts max.

SCR Controlled or 2-4

G Stages 1016941 (Fig. 16) With Option G, can be used
† Proportional
or Vernier Controlled or only when step controller is also
Electronic
K over 4 Stages 1007101 specified
(Fig. 15)

1 Stage G 1023953 (Fig. 18) Rated for 277 volts max.

Pilot
Duty
2 Stage G 1007044 (Fig. 19) Rated for 277 volts. max.
DUCT

SCR Controlled or
2-4 Stages 1016942,
G 1016941 (Fig. 21) With Option G, can be used
† Proportional
or only when step controller is also
Electronic Vernier Controlled or
K specified.
over 4 Stages 101083,
101068 (Fig. 20)

† No Thermostat
(Special inputs for 2200 ohm Input
G —
controller or SCR 135 ohm Input
or —
when customer 4-20 mA Input
K —
supplied thermostat 0-10 VDC Input
is used)

†A thermostat or input must be specified with all Option K heaters and all Option G heaters with step controllers.
Step controllers with 4-20 mA or 0-10 VDC will be furnished with proportional control.

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HUA/HUP – Sample Specification
A job specification can be prepared by using the
following information. Simply darken the applicable
circles. Material which is part of the basic specification
has already been darkened. Additional copies of this
specification guide are available from your local
HEATREX representative.
● 1. Duct heaters shall be HEATREX
○ Type HUA Standard Slip-in Heaters
○ Type HUP Standard Flanged Heaters
● 2. Approvals – Heaters and panelboards (if required)
shall meet the requirements of the National Electrical
Code and shall be listed by Underwriters Laboratories
for zero spacing bewtween the duct and combustible
surfaces and for use with heat pumps and air
conditioning equipment.
● 3. Heating elements shall be open coil, 80% nickel,
20% chromium, Grade A resistance wire. Type C alloys
containing iron or other alloys are not acceptable. Coils
shall be machine crimped into stainless steel terminals
extending at least 1” into the airstream and all terminal
hardware shall be stainless steel. Coils shall be supported
by ceramic bushings staked into supporting brackets.
● 4. Heater frames and terminal boxes shall be
corrosion resistant steel. Unless otherwise indicated,
the terminal box shall be NEMA 1 construction and shall
be provided with a hinged, latching cover and multiple
concentric knockouts for field wiring.
● 5. All heaters shall be furnished with a disc type,
automatic reset thermal cutout for primary over-
temperature protection. All heaters shall also be
furnished with disc type, load carrying manual reset
thermal cutouts, factory wired in series with heater
stages for secondary protection. Heat limiters or other
fusible overtemperature devices are not acceptable.
● 6. Heaters shall be rated for the voltage, phase, and
number of heating stages indicated in the schedule.
All three-phase heaters shall have equal, balanced,
three-phase stages. All internal wiring shall be stranded
copper with 105°C insulation and shall be terminated in
crimped connectors or box lugs.
● 7. Terminal blocks shall be provided for all field
wiring and shall be sized for installation of 75°C copper
wire rated in accordance with NEC requirements.
● 8. Heaters shall be furnished, either with the Control
Option specified in the schedule and described below,
or with the specific components listed in the schedule.
○ Option G – Thermal cutouts, airflow switch,
contactors, fuses (if over 48 amps), control circuit
transformer (where required) and built-in, snap-acting,
door interlocked disconnect switch.
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Standard Duct Heaters
Open Coil
○ Option J – Thermal cutouts, airflow switch, PE
switches, contactors (where required), fuses (if over 48
amps), control circuit transformer (where required), and
built-in snap-acting door interlocked disconnect switch.
○ Option K – Thermal cutouts, airflow switch,
contactors (where required), SCR (with step controller
if heater draws over 96 amps three-phase or 192 amps
single-phase), fuses (if over 48 amps), control circuit
transformer, and built-in snap-acting door interlocked
disconnect switch.
○ 9. When specified in the schedule, or below, heaters
will be supplied with the following Special Features:
○ Airflow switch for negative pressure operation
○ Insulated terminal box
○ Dust-tight terminal box
○ Stainless steel frame and terminal box
○ Aluminized steel frame and terminal box
○ Insulated duct construction for slip-in heaters (>1” ≤6”
thick lining)
○ Unheated section (≤6” terminal pin)
○ Pressure plate
○ Protective screen(s); ○ one side ○ both sides
○ Controls mounted in NEMA 1 remote panelboard
○ Deletion of transformer
○ Deletion of transformer and contactor
○ Transformer primary fusing
○ Transformer secondary fusing (Class II)
○ Additional user control circuit voltages (specify user VA)
○ Deletion of disconnect switch
○ Fused disconnect switch (≤ 48 amps)
○ Fusing for heaters rated 48 amps or less
○ “Low Airflow” pilot light
○ “Heater On” pilot light
○ Each “Stage On” pilot light(s)
○ Fan relay (instead of airlfow switch)
○ Fan relay (in additional to airflow switch)
○ Step controller
○ Linear limit automatic rest thermal cutout
○ 25 watts per square inch resistance coils
○ 35 watts per square inch resistance coils
○ Built-in PE transducer
○ 10. When specified in the schedule, or below, heaters
shall be supplied with the following thermostats:
○ Pilot duty single stage room thermostat
○ Pilot duty digital display single stage room thermostat
○ Pilot duty two stage digital display room thermostat
○ Pilot duty two or three stage programmable with
digital display room thermostat
○ Proportional electronic room thermostat
○ Pilot duty single stage duct thermostat
○ Pilot duty two stage duct thermostat
○ Proportional electronic duct thermostat with set point
adjuster
○ Special inputs (135 ohms, 2200 ohms, 4-20 mA,
0-10 VDC)
31
 Custom Duct Heaters

Special Applications Multi-Zone or Dual Duct Heaters – These heaters

are designed for installation inside multi-zone or dual
Air Conditioning & Air Handling Units – For more
duct air conditioning equipment, where the airflow is
than 55 years, HEATREX has been supplying special
highly variable and unevenly distributed (Figure 51).
heaters for use in air handling and air conditioning
These heaters use coils derated to approximately
equipment (Figure 49). A wide range of special
25 watts per square inch (3.8 watts per square cm)
construction techniques has been developed to insure
of wire surface area (approximately one half normal
proper operation as well as easy installation, either
watt density). Low density coils run cooler, and thus,
in the OEM’s plant or in the field. These heaters
provide longer life under these stringent operating
typically fall into one of the categories described on
conditions.
the following pages.­
These heaters are supplied with fully proportional
SCR control or with many heating stages to
insure that no more heat is being supplied than is
absolutely necessary. Each heater stage is spread
over the entire face area to take advantage of all
available airflow.
A perforated pressure plate is factory-installed on
the air inlet side of the heater to make the airflow
as uniform as possible. Linear limit thermal cutouts
protect against serious overheating anywhere along
the length of the heater.
Figure 49. When the heater must be installed entirely within the
unit, only thermal cutouts are built into the heater,
Modular Construction – The heater is designed a remote panel is required for controls. When the
to match adjacent air handling unit components, terminal box can be external, heaters are available
such as fans, cooling sections, filter boxes, etc. with a wide range of built-in controls.
(Figure 50). Special construction is used so that
the heater mounts adjacent to other components;
the heater becomes simply one module of the air
handling unit assembly. Unheated sections are
provided where there is little or no airflow, such as
the area blocked by an adjacent cooling coil header.
Pressure plates can be provided to insure uniform
airflow, when the heater must be installed adjacent
to the fan. Buffer sections can be furnished to space
the heating coils away from temperature sensitive
components or to help assure uniform airflow.

Figure 51.

Figure 50.

32

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Round Duct Construction – HEATREX
manufactures UL listed open coil duct heaters
specifically designed for installation to commercially
rated round ducts. Heaters are available for
installation to spiral single and double wall or snap-
lock round sheet metal ducts with inside diameters
of 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26 and 28
inches. Two square to round male galvanized
steel transitions, Figure 53, are supplied for field
installation to the inlet and outlet of the duct heater.
The transitions are attached directly to the flanges of
the heater and to the round duct using sheet metal
screws (see Figure 52). The HEATREX transitions
have been approved by UL to provide uniform airflow
across the open coil elements to avoid hot spots,
which could affect the performance of the heater.
Figure 52. Open Coil heater with round duct
transitions. Square Duct
Heater Width
Square Duct
Heater Height
Inside Round
Duct Diameter
Figure 53. Square to round sheet metal transitions.
Marine Duty – Only HEATREX offers a UL Listed
duct heater which is also ABS Approved and meets
U.S. Coast Guard Requirements for shipboard use
(Figure 54).
Figure 54.
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Custom Duct Heaters
Variable Air Volume (VAV) Units – To serve the
fast moving and very competitive VAV market,
HEATREX has developed a fully computerized
design and construction system, which enables us to
ship substantial volumes of heaters in a wide variety
of sizes, ratings, and control options quickly. This
system was patterned after our methods of designing
and producing standard duct heaters, modified to
solve the problems unique to the VAV industry. Slip-
and-drive sheet metal connections, control packages
tailored to VAV systems, and special techniques for
fan interlocks are some of the features designed for
this market (Figure 55).
Figure 55.
Railway and Subway Applications – Tough rail
car industry standards have been developed to
overcome the severe vibration, shock, high operating
voltages, and voltage swings routinely encountered.
For more than 35 years, HEATREX has built
heaters to meet these standards, using heavy gauge
corrosion resistant steel frames and oversized coil
and terminal support bushings (Figure 56).
Figure 56.
33
 Custom Duct Heaters
Duct Heaters for Wet, Dusty and
Corrosive Areas
HEATREX offers a wide selection of custom built
electric duct heater designs for outdoor, wet, dusty,
and corrosive areas. Typical applications include
use with roof top air handling equipment, in
washdown areas such as food processing plants,
wet and humid spaces near indoor swimming pools,
and marine or casino boat applications including
shipboard use.
Features:
• Disconnect switch with door interlock
• Manual reset thermal cutout
• Automatic reset thermal cutout
• Stainless steel frame
• Large diameter stainless steel finned
tubular heating elements
• Heavy duty control transformer
• Fusing per NEC
• Airflow switch
• Stainless steel terminal hardware
Outdoor UL Listed 3R
Figure 57.
Outdoor type 3R heaters (Figure 57) are intended
for outdoor use to provide a degree of protection
against falling rain, sleet, and external ice formation.
UL Listed 3R heaters can be used in most
HVAC outdoor applications and indoors for
protection against dripping water. Water-tight hubs
for incoming power and control connections are
furnished.
34
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Dust-tight Construction
Figure 58.
A dust-tight terminal box (Figure 58) is available to
meet local codes that require dust-tight construction
for a heater installed above a false ceiling when the
entire area is used as a return air plenum. It is also
suitable for commercial or light industrial applications
and to avoid dust accumulation inside the terminal
box while a building is under construction.
These boxes are spot welded corrosion resistant
steel, with all openings sealed. The hinged cover is
gasketed and hold-down clamps are provided. (Note
that this construction does not meet the more rigid
requirements of NEMA 12 described below).
NEMA 12 Type Terminal Box
For heavy duty industrial applications involving both
dust and oil, NEMA 12 construction is available on
custom heaters (Figure 59). The all welded, stainless
steel terminal box has a hinged, gasketed cover with
hold-down clamps. Scru-tite hubs for line and power
connections are included.
Figure 59.
NEMA 4 Type Terminal Box
For weatherproof locations and washdown areas,
such as food processing plants, a NEMA 4 Type
construction is available. This all welded stainless
steel enclosure is furnished with a hinged, gasketed
cover and is provided with water-tight hubs for
incoming power and control connections.
 Custom Duct Heaters

Bottom Mounted Terminal Box Insulated Terminal Box

Figure 61.

When the heater is installed in an air conditioning

Figure 60.
duct which runs through an un-airconditioned
The NEC requires a work space at least 21/2’ (76.2 cm) space, condensation may form inside the terminal
wide by 3½’ (10.67 cm) deep in front of a heater box. To eliminate this condensation or for energy
terminal box for service access. More space is conservation, the back of the terminal box can be
required for large heaters. When this space is not factory insulated (Figure 61). This construction is
available at the side of a duct, the heater can be available with all heaters.
installed through the bottom, using a special bottom
mounted terminal box construction, which maintains Pressure Plates
the required horizontal orientation of open coil 2000
resistance elements. te
1800 P la
e
Custom heaters of either flanged or slip-in design are ur
Air velocity (feet per minute)

1600 s
es
available with this feature. However, slip-in is normally
1400 Pr
preferred for ease of installation (Figure 60). UL Listed o ut
heaters are limited to the sizes indicated in Table XIII. 1200 it h
W
1000
800 late
s ure P
h P re s
Table XIII 600 Wit
400
Duct Size Limitations of Bottom Terminal Box
Heaters 200
0
Heater Minimum W Minimum H Maximum H 0 .02 .04 .06 .08 .10 .12 .14 .16 .18 .20
Type in (mm) in (mm) in (mm)
Pressure drop in inches of water
Open Coil 5 3 40
Flanged (127) (76.2) (1016) Figure 62.

Open Coil 8 4.25 40 A 40% open pressure plate on the inlet side of
Slip-in (203) (108) (1016) open coil type heaters evens out the airflow pattern
in installations where it is not uniform. A pressure
Finned
4.5 4 72
Tubular plate significantly increases the pressure drop
Flanged (114) (102) (1829)
across the heater (Figure 62). This increase must be
Finned considered in sizing the fan motor. To assure correct
Tubular 11 5.25 72
plate location, specify the exact airflow direction as
Slip-in (279) (133) (1829)
defined in Figures 42 and 43, page 23.

35

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 Custom Duct Heaters

Protective Screens Construction For Lined Ducts

Figure 63.

Figure 65. Installation of flange type heater in lined

Protective screens protect personnel from accidental
duct
contact with electrically hot open coil elements and
prevent large airborne contamination from reaching
the elements (Figure 63). The 3/8” (9.5mm) wire
mesh screen may be mounted on both sides of the
heater. Finned tubular duct heater construction may
be more appropriate for these applications.

Unheated Sections

Figure 66. Installation of slip-in heater where

insulation is more than 1” (25.4 mm) thick

All HEATREX slip-in heaters are suitable for use

Figure 64.
HEATREX custom heaters can be supplied with
unheated sections, either open or blocked off
(Figure 64). Such constructions are particularly
helpful when the heater frame must extend
through an area with little or no airflow to maintain
accessibility to the terminal box. For example, a
heater next to a cooling coil should have extended
terminal pins so no heat is generated adjacent to the
cooling coil header. Most constructions are available
with a UL label.
in ducts lined with up to 1” (25.4 mm) of interior
insulation. Extended terminals and the design of
the thermal cutout system make standard slip-in
heaters suitable for such installations without any
deterioration in performance or life. Be sure that the
duct dimensions specified are those inside the duct
lining.
For slip-in heater applications where the insulation
is more than 1” (25.4 mm) thick or where flanged
heaters are required, the special constructions
illustrated in Figures 65 and 66. Dimensions inside
the insulation must be specified as well as the
insulation thickness.

36

www.heatrex.com

Slip-and-Drive Construction
Figure 67.
This option for custom flanged heaters, allowing
installation with conventional HVAC slip-and-drive
connections, offers the rugged and secure mounting
of a flanged heater, yet requires less installation labor
than a slip-in heater. It is particularly useful when other
equipment in the duct system uses slip-and-drive
connections, as the contractor can standardize
throughout (Figure 67).
By using HEATREX’s slip-and-drive construction in
variable air volume (VAV) units, the manufacturer
can offer the same standard VAV box for electric
heat, hot water heat, or no heat.
Remote Panelboard
When specifying remote panelboards (Figure 68),
we recommend the following changes in control
and safety components to insure the safety of the
installation and to minimize the field labor costs.
• Contactors – Use disconnecting controlling
contactors which break all ungrounded lines. Thus,
when heat is not being called for, all terminals in
the heater will be dead.
Figure 68.
Custom Duct Heaters
• Pilot Switch – Add a dead front pilot switch
to the heater terminal box to make it safe for
servicing by simply tripping the pilot switch. This
shuts off power to the heater circuits through the
disconnecting contactors in the panel.
• Fuses – Built-in fusing for each panelboard will be
in accordance with UL and NEC requirements.
Except for SCR’s, which are mounted through
the panelboard side wall, control components are
mounted on a sub-panel. Labeled terminal blocks
are provided for all field wiring, both in the panel and
in the heater. Knockouts and wiring gutter spaces
are supplied in all panelboards.
NEMA 1 panels are made from heavy gauge steel,
welded and painted (as required), and are provided
with a lock and key. Wall mounting, flush mounting,
or floor mounting on legs are available.
NEMA 3R type panelboards for outdoor use are
UL Listed. These are intended for outdoor use to
provide protection against falling rain, sleet, and
external ice formation.
NEMA 4 and NEMA 12 panelboards for outdoor,
dusty, and oil atmospheres are also available, as
well as explosion-proof panels furnished with cast
aluminum enclosures.
All standard type HUA and HUP heaters are
available with remote panels. Panels for these
standard heaters are available in NEMA 1 wall
mounting only. Fusing, disconnecting contactors,
and a heater-mounted pilot switch, all as described
above, are supplied.
37
 Custom Duct Heaters

Minimum & Maximum Duct Dimensions

Although there is no limitation on the maximum size
of custom heater assemblies, individual UL Listed
heaters must meet the following minimum and
maximum requirements (see tables below).
UL listed custom heaters are also available in
virtually any KW rating. However, heaters are
restricted to maximum KW ratings based on the
square feet of heated area.
HEATREX has built individual duct heaters for space
heating applications ranging from 0.1 KW to over
900 KW, multi-section units with up to 2000 KW in
one assembly, and face areas as large as 40’ wide
x 14’ high. Exact dimensional and KW limits
can be determined by contacting your local
HEATREX representative.

Table XIV Table XV

Open Coil Custom Heaters Finned Tubular Custom Heaters

Slip-in Type Flanged Type Slip-in Type Flanged Type

in (mm) in (mm) in (mm) in (mm)
Minimum Duct  5.25 (133) 5 (127) Minimum Duct 4.75 (121) 4.5 (114)
Width (W) Width (W)
Minimum Duct 4.25 (108) 3 (76) Minimum Duct 5.25 (133) 4 (102)
Height (H) Height (H)
Maximum Duct Maximum Duct
240 (6100) 240 (6100) 175 (4450) 175 (4450)
Width (W) Width (W)
Maximum Duct 120 (3050) 120 (3050) Maximum Duct 120 (3050) 120 (3050)
Height (H) Height (H)

Figure 69. Slip-in duct heater Figure 70. Flanged duct heater

38

www.heatrex.com

Open Coil Custom Heater – Sample Specification
A job specification can be prepared by using
the following information. Simply darken the
applicable circles. Material which is part of the basic
specification has already been darkened. Additional
copies of this specification guide are available from
your local HEATREX representative.
● 1. Duct heaters shall be HEATREX:
Type XUB Custom Slip-in Heater
Type ZUB Custom Flanged Heater
● 2. Approvals – Heaters and panelboards (if
required) shall meet the requirements of the National
Electrical Code and shall be listed by Underwriters
Laboratories for zero spacing between the duct and
combustible surfaces and for use with heat pumps
and air conditioning equipment.
● 3. Heating elements shall be open coil, 80%
nickel, 20% chromium, Grade A resistance wire.
Type C alloys containing iron or other alloys are
not acceptable. Coils shall be machine crimped into
stainless steel terminals extending at least 1” into the
airstream and all terminal hardware shall be stainless
steel. Coils shall be supported by ceramic bushings
staked into supporting brackets.
● 4. Heater frames and terminal boxes shall be
corrosion resistant steel. Unless otherwise indicated,
the terminal box shall be NEMA 1 construction and
shall be provided with a hinged, latching cover and
multiple concentric knockouts for field wiring.
● 5. All heaters shall be furnished with a disc
type, automatic reset thermal cutout for primary
overtemperature protection. All heaters shall also
be furnished with disc type, load-carrying manual
reset thermal cutouts, factory wired in series with
heater stages for secondary protection. Heat limiters
or other fusible overtemperature devices are not
acceptable.
● 6. Heaters shall be rated for the voltage, phase,
and number of heating stages indicated in the
schedule. All three-phase heaters shall have equal,
balanced, three-phase stages. All internal wiring
shall be stranded copper with 105°C insulation and
shall be terminated in crimped connectorsor box lugs.
● 7. Terminal blocks shall be provided for all
field wiring and shall be sized for installation of
75°C copper wire, rated in accordance with NEC
requirements.
● 8. Heaters shall be furnished, either with the
Control Option specified in the schedule and
described below, or with the specific components
listed in the schedule.
○ Option G – Thermal cutouts, airflow switch,
contactors, fuses (if over 48 amps), control circuit
transformer (where required) and built-in snap-acting
door interlocked disconnect switch.
○ Option J – Thermal cutouts, airflow switch,
PE switches, contactors (where required), fuses (if
over 48 amps), control circuit transformer (where
required) and built-in snap-acting door interlocked
disconnect switch.
Custom Duct Heaters
○ Option K – Thermal cutouts, airflow switch,
contactors (where required), SCR (with step controller
and contactors, if heater draws over 96 amps, three-
phase or 192 amps single-phase), fuses (if over 48
amps), control circuit transformer (where required),
and built-in snap-acting door interlocked disconnect
switch.
○ 9. When specified in the schedule, or below, heaters
will be supplied with the following Special Features:
○ Airflow switch for negative pressure operation
○ Insulated terminal box
○ Dust-tight terminal box
○ Special terminal box construction
○ NEMA 1 ○ UL3R ○ NEMA 12 ○ NEMA 4 ○ NEMA 4X
○ Stainless steel frame and terminal box
○ Aluminized steel frame and terminal box
○ Insulated duct construction for slip-in heaters
○ Unheated section
○ Pressure plate
○ Protective screen(s); ○ one side ○ both sides
○ Controls mounted in remote panelboard
○ NEMA 1 ○ UL3R ○ NEMA 12 ○ NEMA 4 ○ NEMA 4X
○ Deletion of transformer
○ Delection of transformer and contactor
○ Transformer primary fusing
○ Transformer secondary fusing (Class II)
○ Additional user control circuit voltage (specify user VA)
○ Deletion of disconnect switch
○ Fused disconnect switch (≤ 48 amps)
○ Fusing for heaters rated 48 amps or less
○ “Low Airflow” pilot light
○ “Heater On” pilot light
○ “Overtemperature” pilot light
○ Each “Stage On” pilot light(s)
○ Fan relay (instead of airflow switch)
○ Fan relay (in addition to airflow switch)
○ Step controller
○ Linear limit automatic rest thermal cutout
○ 25 watts per square inch resistance coils
○ 35 watts per square inch resistance coils
○ Built-in PE transducer
○ Round Duct Construction
○ 10. When specified in the schedule, or below,
heaters shall be supplied with the following
thermostats:
○ Pilot duty single stage room thermostat
○ Pilot duty digital display single stage room
thermostat
○ Pilot duty two stage digital display room thermostat
○ Pilot duty two or three stage programmable with
digital display room thermostat
○ Proportional electronic room thermostat
○ Pilot duty single stage duct thermostat
○ Pilot duty two stage duct thermostat
○ Proportional electronic duct thermostat with set point
adjuster
○ Special inputs (135 ohms, 2200 ohms, 39
4-20 mA, 0-10 VDC)
 Custom Duct Heaters
Finned Tubular Custom Heater – Sample Specification
A job specification can be prepared by using the
following information. Simply darken the applicable
circles. Material which is part of the basic specification
has already been darkened. Additional copies of
this specification guide are available from your local
HEATREX representative.
● 1. Duct heaters shall be HEATREX:
Type TFXU Custom Slip-in Heater
Type TFPU Custom Flanged Heater
● 2. Approvals – Heaters and panelboards (if
required) shall meet the requirements of the National
Electrical Code and shall be listed by Underwriters
Laboratories, for zero spacing between the duct and
combustible surfaces, and for use with heat pumps,
and air conditioning equipment.
● 3. Heating elements shall consist of coil, 80%
nickel, 20% chromium, Grade A resistance wire,
precisely centered in a stainless steel tube filled with
granular magnesium oxide. A stainless steel fin is
to be helically wound onto the tube. Elements are
to be furnished with mounting flanges, making them
individually removable through the terminal box.
● 4. Heater frames and terminal boxes shall be
corrosion resistant steel. Unless otherwise indicated,
the terminal box shall be NEMA 1 construction and
shall be provided with a hinged latching cover and
multiple concentric knockouts for field wiring.
● 5. All heaters shall be furnished with triple
overtemperature protection. A disc type and linear,
automatic reset thermal cutout are included for
primary overtemperature protection. All heaters must
also be furnished with a linear type manual reset
thermal cutout with backup contactors (as required).
For secondary overtemperature protection, heat
limiters or other fusible overtemperature devices are
not acceptable.
● 6. Heaters shall be rated for the voltage, phase,
and number of heating stages indicated in the
schedule. All three-phase heaters shall have equal
balanced three-phase stages. All internal wiring shall
be stranded copper with 105°C insulation and shall be
terminated in crimped connectors or box lugs.
● 7. Terminal blocks shall be provided for all
field wiring and shall be sized for installation of
75°C copper wire rated in accordance with NEC
requirements.
● 8. Heaters shall be furnished either with the
Control Option specified in the schedule and
described below or with the specific components listed
in the schedule.
Option G – Thermal cutouts, airflow switch,
contactors, fuses (if over 48 amps), control circuit
transformer (where required) and built-in snap-acting
door interlocked disconnect switch.
40
www.heatrex.com
Option J – Thermal cutouts, airflow switch, PE
switches, contactors (where required), fuses (if over
48 amps), control circuit transformer (as required), and
built-in snap-acting door interlocked disconnect switch.
Option K – Thermal cutouts, airflow switch, contactors
(where required), SCR (with step controller if heater
draws over 96 amps three-phase or 192 amps
single-phase), fuses (if over 48 amps), control circuit
transformer (where required) and built-in, snap-acting,
door interlocked disconnect switch.
9. When specified in the schedule, or below, heaters
will be supplied with the following Special Features:
Airflow switch for negative pressure operation
Insulated terminal box
Dust-tight terminal box
Special terminal box construction
○ NEMA 1○ UL3R ○ NEMA 12 ○ NEMA 4 ○ NEMA 4X
Stainless steel frame and terminal box
Aluminized steel frame and terminal box
Insulated duct construction for slip-in heaters
Unheated section
Controls mounted in remote panelboard
○ NEMA 1 ○ UL3R ○ NEMA 12 ○ NEMA 4 ○ NEMA 4X
Deletion of transformer
Deletion of transformer and contactor
Transformer primary fusing
Transformer secondary fusing (Class II)
Additional user control circuit voltage(specify user VA)
Deletion of disconnect switch
Fused disconnect switch (≤ 48 amps)
Fusing for heaters rated 48 ampes or less)
“Low Airflow” pilot light
“Heater On” pilot light
“Overtemperature” pilot light
Each “Stage On” pilot light(s)
Fan relay (instead of airflow switch)
Fan relay (in addition to airflow switch)
Step controller
Built-in PE transducer
10. When specified in the schedule, or below, heaters
shall be supplied with the following thermostats:
Pilot duty single stage room thermostat
Pilot duty digital display single stage room thermostat
Pilot duty two stage digital room thermostat
Pilot duty two or three stage programmable with
digtial display room thermostat
Proportional electronic room thermostat
Pilot duty single stage duct thermostat
Pilot duty two stage duct thermostat
Proportional electronic duct thermostat with set point
adjuster
Special inputs (135 ohms, 2200 ohms,
4-20 mA, 0-10 VDC)
 Explosion-proof Duct Heaters
Safety
HEATREX explosion-proof ULTRA-SAFE™ and
EP2 duct heaters are Factory Mutual (FM) and CSA
Approved. The ULTRA-SAFE™ duct heater has
the only standard product offering and features the
industry’s lowest ignition temperature code rating,
T3C, 320°F (160°C).
Experience
This catalog represents more than 75 years
experience in industrial electric heating, our
specialty since HEATREX was founded in 1929.
HEATREX has more than 55 years experience with
forced air comfort heating for hazardous locations.
Complete Product Line
• Industry’s most comprehensive product line of
space heating equipment.
• Ratings up to 750 KW and 600 volts.
• Widest selection of built-in controls.
Applications
HEATREX Duct Heaters provide a clean, safe
source of electric heat for comfort heating and
freeze protection in hazardous locations where
specific explosive gases or dusts are present, and
environments where moisture and corrosion exist.
www.heatrex.com
Use of Electric Heaters in Hazardous
Areas
Electric heating equipment can be economically
designed and safely used in hazardous areas, if the
following special requirements are kept in mind.
1. T
 he surface temperature of the electric
heating equipment cannot exceed the ignition
temperature of the hazardous atmosphere. To
insure that the proper heater has been selected,
it is essential that the correct NEC Ignition
Temperature Code be specified (see Table XVI).
If the temperature code selected is too high,
the electric heating system may operate above
the ignition point of the application, creating a
potentially hazardous condition.
2. A
 ll arc and spark producing control devices must
be isolated from the hazardous atmosphere. If it
is not economically feasible to locate the control
devices in a non-hazardous area, they must be
housed in an enclosure that will withstand the
pressure of a potential explosion from within the
enclosure.
3. A
 ll electrical supply connections must be made
according to the latest NEC and local code
requirements for hazardous locations. This
includes the requirement that conduit entering
the enclosures must be provided with seals at the
enclosure.
®�
41
 Explosion-proof Duct Heaters

Hazardous locations are those areas where a

Class
potential for explosion and fire exists due to the Hazardous locations are divided into the three general
presence of flammable gases, vapors, pulverized classes of vapors/gases, dusts, and fibers.
dusts, or ignitable fibers in the atmosphere. Class I – Locations where the potential for explosion
Hazardous locations are created from the normal and fire exists due to the presence of flammable
processing of volatile chemicals, gases, coal, grains, gases or vapors in the air. Typical Class I locations
etc., or from the accidental failure of storage systems include: oil or natural gas drilling rigs, petroleum
for these materials. refining or pumping facilities, petrochemical plants,
Both people and equipment in hazardous locations wastewater/ sewage treatment plants, solvent
can be heated safely and economically with extraction plants, paint spraying booths, locations
electric heat. Electric heating is typically much less where open tanks or vats of combustible liquids are
expensive to install and maintain than comparable present, and storage areas for flammable materials.
remote oil or gas fired heating systems. Class II – Locations where the potential for explosion
exists because of finely pulverized flammable dusts
suspended in the atmosphere. Typical locations would
Table XVI include coal fired power plants, coal preparation/coal
Ignition Temperature handling facilities, coal mines, grain elevators, flour
and feed mills, packaging and handling of pulverized
Maximum Surface NEC sugar, processing and storage of magnesium and
Temp. Of Heater* Ignition Temp.
aluminum powder.
°C °F Code
450 842 T1 Class III – This third classification is primarily a
fire hazard where fibers or flyings suspended in
300 572 T2
the air create a hazard. This would include small
280 536 T2A pieces of thread like fiber, sawdust, lint, etc. Typical
260 500 T2B applications would include: textile mills, woodworking
230 446 T2C plants, cotton gins and cotton seed mills, and flax
producing plants.
215 419 T2D
200 392 T3 Division
180 356 T3A
Class I, Class II, and Class III areas are further
165 329 T3B defined in terms of when the hazard occurs. Division
160 320 T3C 1 and Division 2 occurrences are summarized below:
*All electrical equipment is designed not to exceed the
ignition temperature of the hazardous atmosphere. The Division 1 – If the hazard is expected to be present
maximum surface temperature for electric heaters is under normal conditions, such as in a production
defined by the NEC for each class as indicated above.
or processing facility, the occurrence is designated
Division 1. The hazardous atmosphere may be
present continuously, intermittently, periodically, or
during normal repair or maintenance operations.
Division 1 occurrences also include locations where a
National Electrical Code Classification breakdown in the operations of processing equipment
Articles 500 through 516 of the National Electrical results in the release of hazardous vapors.
Code deal with the definition of hazardous areas Division 2 – If the hazardous material is normally
and the use or design of electrical equipment used expected to be contained within a closed area,
in these locations. Electric heating equipment for system or container and would enter the ambient
hazardous areas is specified based on the NEC atmosphere only under an abnormal failure, then it is
Class, Division, Group, and Ignition Temperature. referred to as a Division 2 occurrence.

42

www.heatrex.com
 Explosion-proof Duct Heaters

Group Class II – Hazardous dust locations are divided into three

The nature and explosive characteristics of the
hazardous material is defined by the NEC group to
which it is assigned.
Class I – Hazardous gas locations include chemicals
and other materials that have been divided into four
groups based on their ignition temperature and
explosive characteristics. (Groups A, B, C and D)
Table XVII
groups based on their ignition temperature and electrical
conductivity of the suspended particles.
Group E – Atmospheres containing metal dusts such as
aluminum and magnesium.
Group F – Atmospheres containing coal, charcoal, or coke
dusts.
Group G – Atmospheres with grain, flour, starch,
combustible plastics, or chemical dusts.
Class III – Locations have no group definitions.

CLASS I - HAZARDOUS GAS ATMOSPHERES CLASS I - HAZARDOUS GAS ATMOSPHERES

Ignition Temp. NEC Ignition Temp. NEC
Group Material °F °C Code Group Material °F °C Code
A Acetylene 581 305 T2 D Methyl Isobutyl Ketone 840 448 T2
B Acrolein (Inhibited) 428 220 T2D 2-Methyl-1-Propanol 780 415 T2
Butadiene 788 420 T2 (Isobutyl Alcohol)
Ethylene Oxide 804 429 T2 Petroleum Naptha 550 288 T2A
Hydrogen 932 500 T1 Pyridine 900 482 T1
Propylene Oxide 840 449 T2 Octanes 403 206 T3
Propyl Nitrate 347 175 T3B Pentanes 500 260 T2B
C Acetaldehyde 347 175 T3B 1-Pentanol (Amyl Alchohol) 650 343 T2
Allyl Alcohol 713 378 T2 Propane 842 450 T1
Carbon Monoxide 1128 609 T1 1-Propanol (Propyl Alchohol) 775 412 T2
Cyclopropane 928 498 T1 2-Propanol (Isopropyl Alcohol) 750 399 T2
Ethylene 842 450 T1 Propylene 851 455 T1
Hydrogen Cyanide 1000 538 T1 Styrene 914 490 T1
Hydrogen Sulfide 500 260 T2B Toluene 896 480 T1
2-Nitropropane 802 428 T2 Vinyl Acetate 756 402 T2
Tetrahydrofuran 610 321 T2 Vinyl Chloride 882 472 T1
D Acetic Acid (Glacia) 867 463 T1 Xylenes 867- 463- T1
Acetone 869 465 T1 984 528
Ammonia, Anhydrous 1204 651 T1 CLASS II - HAZARDOUS DUST ATMOSPHERES
Benzene 928 498 T1 Ignition Temp. NEC
Butane 550 287 T2A Group Material °F °C Code
1-Butanol (Butyl Alcohol) 650 343 T2 E Aluminum, A422 Flake 608 320 T2
2-Butanol 761 405 T2 Calcium Silicide 1004 540 T1
(Secondary Butyl Alcohol) Manganese 464 240 T2C
Ethane 882 472 T1 Magnesium, Grade B, Milled 806 430 T2
Ethanol (Ethyl Alcohol) 685 363 T2 F Charcoal 356 180 T3A
Ethyl Acetate 800 427 T2 Coal, Kentucky Bituminous 356 180 T3A
Ethylene Dichloride 775 413 T2 Coal, Pittsburgh Experimental 338 170 T3B
Gasoline (56-60 Octane) 536 280 T2A Pitch, Petroleum 1166 630 T1
Gasoline (100 Octane) 853 456 T1 G Alkyl Ketone Dimer 320 160 T3C
Heptanes 399 204 T3 Sizing Compound
Hexanes 437 235 T2D Corn 482 250 T2C
Isoprene 428 220 T2D Corn Starch, Modified 392 200 T3
Isopropyl Ether 830 443 T2 Polyurethane Foam, 734 390 T2
Methane (Natural Gas) 900- 482- T1 Fire Retardant
1170 632 Shellac 752 400 T2
Methanol (Methyl Alcohol) 867 454 T1 Soy Flour 374 190 T3A
3-Methyl-1-Butanol 662 350 T2 Sugar, Powdered 698 370 T2
(Isoamyl Alcohol) Sulfur 428 220 T2D
Methyl Ethyl Ketone 759 404 T2 Wheat 428 220 T2D 43
Wood Flour 500 260 T2B
The materials given are found in NEPA 497M, 1991 and NFPA 325, 1994.
 Explosion-proof Duct Heaters
12

KW Per Square Foot Of Heat Exchanger Area

Engineering Information  
National Electrical Code Requirements for Duct 10

Heaters In addition to the general requirements
for hazardous areas on pages 42 and 43, the 
NEC also requires that all duct heaters have 8

built-in protection against low airflow, primary 

and secondary overtemperature protection, and
overcurrent protection for heaters drawing more than 6

48 amps. These safety features are provided with all 

HEATREX explosion-proof duct heaters.
4

Airflow Requirements
Airflow must be calculated to give the required 2
temperature rise and to ensure sufficient airflow 100 300 500 700 900 1100 1300 1500

to prevent the thermal cutouts from tripping Figure 72. Minimum air velocity required for
227 Series, feet per minute
prematurely. (meters per minute)
Required air volume to give the desired 8

KW Per Square Foot Of Area

temperature rise for a given KW is determined by
the formula: SCFM = KW x 3193/∆T where SCFM
is airflow volume in Standard Cubic Feet per Minute 6
and ∆T is temperature rise in °F.
Minimum air velocity for safe operation is 4
determined by dividing the heater KW by the cross-
sectional duct area: KW / Sq. Ft. = KW / (W x H / 144)
2
where W and H are duct width and height in inches. 0 200 400 600 800
For 227 Series duct heaters, use the minimum (61) (122) (183) (244)
W x H dimensions shown in the Heater Listing Figure 73. Minimum air velocity required
on page 48. Read the minimum velocity from the for 220 Series feet per minute
(meters per minute)
horizontal axis of Figure 72 for 227 Series Duct
Heater or Figure 73 for 220 Series heaters.
Unit Size Codes
Airflow must be uniform over the face of the 3
▲ A, C, B, D, E & F
heater, and must be horizontal for all but Custom 2.8
□ G, H, J, K, L & M
Explosion-proof Duct Heaters. 2.6 N, P, O, R, S & T
 
U, V, W, X,Y & Z
 
Horizontal airflow direction is defined in Figure 71. 2.4

Pressure drop through the heater can be 2.2

Pressure Drop, Inches Of Water

determined by using Figure 74 for the 227 Series 2

duct heater.
1.8

1.6

1.4

1.2

0.8

0.6

0.4

0.2

0
100 200 300 400 500 600 700 800 900 1000 1200 1300 1400 1500
Figure 71.
Air Velocity, Feet Per Minute
44 Figure 74. 227 Series
Pressure Drop Curve
 Explosion-proof Duct Heaters
Engineering developments at HEATREX have made
electric duct heaters for hazardous locations readily
available at affordable prices.

227 Series
• FM and CSA Approved for virtually all Class I and
Class II, Division 1 and 2 hazardous gas or dusty
atmospheres
• Ignition temperatures as low as 320°F (160°C)
• Six standard sizes to fit a wide range of ducts
Figure 75. 227 Series Explosion-proof Duct Heater
• Ratings up to 240 KW, 600 volts

220 Series
• FM and CSA Approved for Class I, Division 2
locations where a hazardous gas is occasionally
present
• Ignition temperatures as low as 392°F (200°C)
• For ducts up to 240” (610 cm) wide by 120”
(305 cm) high
• Ratings up to 1000 KW, 600 volts Figure 76. 220 Series Explosion-proof Duct Heater
Custom
• Wider range of sizes than available in the other
two designs
• Vertical airflow
• Ratings up to 750 KW, 600 volts

Table XVIII Figure 77. Custom Explosion-proof Duct Heater

Comparison Chart
NEC
KW and Ignition
Heater Type Control Class and Division Tempera- Special Considerations
Range ture
Code
227 Series Up to 240 KW Class I, Divisions 1 T3C • Fastest delivery of the three designs
For hazardous gas and 2, 320 °F • Available for outdoor or wet locations
or dust atmospheres. Single stage Groups B, C and D (160 °C) • Corrosion resistant construction available
Fits ducts from or SCR Control • Horizontal airflow only
12”W x 12” H to Class II, Divisions 1 • Not approved for shipborad use
75”W x 35” H. and 2, • Flanged mounting
Groups E, F and G
220 Series Up to 1000 KW Class I, Division 2, T3 • Available for outdoor or wet locations
For Division 2 Groups C and D 392 °F • May be less expensive than 227 Series
hazardous gases Multi-stage (200 °C) for larger KW designs
(hazard exists only or SCR Control • Horizontal airflow only
occasionally). • Approved for shipboard use
• Flanged mounting
Custom Up to 750 KW Class I, Divisions 1 T1 • Horizontal or vertical airflow
Designed for each and 2, 842 °F • Slip-in or flanged mounting
project. Multi-stage Groups C and D (450 °C) • For ducts smaller than 12” x 12”
Not FM or CSA Ap- or SCR Control through • Available for outdoor or wet locations
provded. Class II, Divisions 1 T3B
and 2, 329 °F 45
Groups E, F and G (165 °C)
 227 Series
Explosion-proof Duct Heaters
Standard Construction • Grounding terminal.
Heat Exchanger has copper tubes with integral • Supplemental fusing for heaters drawing more
aluminum fins. Each unit undergoes hydrostatic than 48 amps.
testing at 350 psig, five times the pressure relief
valve setting of 70 psig. Installation
Heat Transfer Fluid is propylene glycol, a non-toxic, Complete installation instructions are furnished with
rust-inhibiting fluid that provides freeze protection each heater. Following are some guidelines:
to –49°F (–45°C). Its high heat transfer rate at
• The heater must be securely attached to external
70 psig makes the heat exchanger suitable for
duct flanges.
gases that ignite at temperatures as low as 320°F
(160°C). Thus every 227 Series heater is rated for • The heater must be adequately supported. If
Temperature Code T3C. the duct flanges will not afford enough support,
overhead hangers attached to the lifting lugs may
Industrial Grade Heating Elements, built by
be used for additional support.
HEATREX, are .475” (1.21 cm) diameter to provide
extra insulation between the coil and sheath for high • Each heater is suitable for a variety of duct sizes.
voltage protection. See Table XIX on page 48 for maximum and
minimum dimensions. Note that duct height and
Frame is heavy gauge galvanized steel, fitted with
width can vary independently.
lifting lugs to facilitate installation.
• Airflow must be horizontal. See page 44 for airflow
Four Levels of Safety are provided on every heater:
requirements.
automatic and manual reset thermal cutouts, airflow
interlock, and pressure relief valve.
Attach hanger rods to structure capable of supporting
Two thermal cutouts limit the heat transfer fluid the weight of the heater.
temperature, assuring thermal safety. The automatic Ensure attachment allows for height adjustment so
reset operates a “primary” magnetic contactor. The that heater is level along both axis.
manual reset operates a separate backup magnetic
contactor. If either cutout opens, the entire heater is All field conduit
must be adequately
de-energized. supported and
comply with all
code requirements.
A fan relay, acting as an airflow interlock, prevents
the heater from being energized unless the fan
starter is on.
The pressure relief valve on the heat exchanger
opens only if the thermal cutout system fails to
prevent excessive temperatures.
Standard Built-in Control Package includes the
following components mounted in a cast aluminum
explosion-proof enclosure:
• De-energizing control and back-up magnetic 1” minimum range typical
all the way around.
contactors.
• 24V control circuit transformer. Maximum duct dimensions Minimum duct dimensions
(WMax & HMax) should allow (WMin & HMin) are same as
• Fan relay, supplied with 24V or 120V holding coil for 1” minimum flange all heat exchanger dimensions.
around.
to match the fan starter coil voltage.
• Terminal blocks for field power and control wiring. Figure 78. 227 Series mounting configuration

Classes I and II, Division 1 and 2

Groups B, C, D, F and G
Temperature Code
T3C, 320°F (160°C)
46
®�
Ratings Available
• Up to 240 KW www.heatrex.com
• Up to 600V
 220 Series
Explosion-proof Duct Heaters
Temperature Control inputs of 2200 or 135 ohms, 0-10 VDC, or 4-20
mA. SCR’s have zero-cross firing to eliminate radio
Single Stage Control – For many lower KW
frequency interference.
applications, single stage on/off control is adequate.
For higher KW ratings, solid-state SCR control is To meet FM and CSA requirements, multi-unit
recommended. designs (up to four heating units in series) also
have controls set at 80°F (27°C) to limit the inlet
Solid-State SCR Control – When temperature must
air temperature to all but the inlet unit. These limit
be controlled precisely, or for larger KW heaters,
controls prevent excessive temperatures at the
built-in SCR’s manufactured by HEATREX are
heater outlet as the inlet air temperature rises.
recommended. They are furnished with field-selected

Figure 79. Heater with single

stage control

Figure 80. Heater with SCR control

and options D, L and P
47

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 227 Series
Explosion-proof Duct Heaters
Table XIX
Standard Heater Listing

Catalog Unit Size KW Range Inside Duct Dimensions(4) - in (cm) Depth (3) Weight (3)
Number Code Fig. Min. Max. Minimum(2) W X H Maximum(1) W X H in (cm) lb (kg)
HX-227F30A A 79A
79A 3 10 8 (20) 130 (59)
HX-227F30G G 6 20 12 X 12 18 X 24 16 (41) 260 (118)
HX-227F30N N 9 30 (30.5 X 30.5) (45.7 X 61) 24 (61) 680 (308)
HX-227F30U U 12 40 32 (81) 710 (322)
HX-227F30B B 3 20 12 (31) 150 (68)
HX-227F30H H 6 40 16.5 X 16 22.5 X 28 24 (61) 300 (136)
81
HX-227F30P P 9 60 (41.9 X 40.6) (57 X 71) 36 (91) 730 (331)
HX-227F30V V 12 80 48 (122) 770 (349)
HX-227F30C C 10 30 12 (31) 200 (91)
HX-227F30J J 20 60 21 X 21 27 X 35 24 (61) 400 (181)
HX-227F30Q Q 30 90 (53.3 X 53.3) (69 X 89) 36 (91) 860 (390)
HX-227F30W W 40 120 48 (122) 940 (426)
HX-227F30D D 79B 6 20 8 (20) 260 (118)
HX-227F30K K 12 40 24 X 12 34 X 24 16 (41) 470 (213)
HX-227F30R R 18 60 (61 X 30.5) (86 X 61) 24 (61) 970 (440)
HX-227F30X X 24 80 52 (32) 1090 (494)
HX-227F30E E 6 40 12 (31) 300 (136)
HX-227F30L L 12 80 33 X 16 43 X 28 24 (61) 550 (249)
82
HX-227F30S S 18 120 (83.8 X 40.6) (109 X 71) 36 (91) 1080 (490)
HX-227F30Y Y 24 160 48 (122) 1240 (562)
HX-227F30F F 20 60 12 (31) 390 (177)
HX-227F30M M 40 120 42 X 21 52 X 35 24 (61) 730 (331)
HX-227F30T T 60 180 (106.7 X 53.3) (132 X 89) 36 (91) 1350 (612)
HX-227F30Z Z 80 240 48 (122) 1600 (726)

(1) Consult factory for availability of other maximum inside duct dimensions.
(2) Use only Minimum W x H dimensions for minimum air velocity calculations (see page 44).
(3) Depth and weights shown for catalog listed KW ratings. They will be greater for larger KW and non-catalog designs.
(4) Duct height and width can vary independently of minimum and maximum dimensions.

Figure 81. Figure 82.

1 Heat Exchanger Module 2 Heat Exchanger Modules

48

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 227 Series
Explosion-proof Duct Heaters
Table XX
Custom Options

Option Description Code

Corrosion Resistant Stainless frame, coated heat exchanger, epoxy-coated NEMA 4X, 7, 9 terminal
C
Construction box, conduit and fittings.
Built-On To meet NEC requirement for a disconnect at or within sight of the heater.
D
Disconnect Switch (Not available for outdoor, washdown or Groups B, E, F, G)
An explosion-proof differential pressure switch replaces the fan relay. Use only
Built-on Airflow
for positive pressure inside the duct. (Not available for outdoor, washdown or P
Switch
Group B).
Supplementary
For heaters drawing 48 amps or less. Fusing is standard above 48 amps. F
Fusing
“Warning”
Red light to indicate when a thermal cutout or airflow interlock has tripped. K
Pilot Light
“Heater On”
Green light indicates when there is power to the heater. L
Pilot Light
Disconnecting Contactors that break all ungrounded lines replace standard de-energizing
M
Magnetic Contactors contactors.
120 Volt A 120V control transformer with one leg fused replaces the standard 24V trans-
V
Control Circuit former. (Not available with solid-state SCR control.)
NEMA 4
Explosion-proof box is gasketed for outdoor or wet locations. G
Construction
Group B For Class I, Group B areas. Heater will be rated for Classes I and II;
Z
Construction Divisions 1 and 2; Groups B, C, D, E, F and G.

Figure 83. Built-on airflow switch Figure 84. Built-on disconnect switch

Classes I and II,

Division 1 and 2
Groups B, C, D, F 49
and G
®�
Temperature Code
www.heatrex.com T3C, 320°F (160°C)
 227 Series
Explosion-proof Duct Heaters
How to Order
1. C
 atalog No. or Size – Specify Catalog Number
from Table XIX on page 48.
2. K
 W Rating – Up to the maximum shown in
Table XIX.
3. Heater Voltage and Phase
4. Temperature Control – Single Stage or
SCR Control. If SCR Control, specify input signal.
5. F
 an Relay Voltage – Specify 24 or 120 volt to
match fan starter holding coil voltage.
6. Airflow Direction – Horizontal Right-Hand or Left-
Hand airflow, as defined on page 44.
7. M
 aximum Inlet Air Temperature – Maximum
of 80° F (27° C). If inlet air will be higher, consult
factory.
8. O
 ptions – Select from 227 Series Custom Option
codes in Table XX.
Sample Specification
A sample specification can be prepared by using
the following information. A circle has been supplied
so that you may darken those sections which you
require. Material which is part of the standard 227
Series Explosion-proof Duct Heater specification has
already been darkened.
● 1. Electric explosion-proof duct heaters shall be
HEATREX 227 Series, of the KW rating, voltage,
phase, duct size and airflow direction specified in
the schedule. They shall be Factory Mutual and CSA
Approved for:
● C
 lass I, Divisions 1 and 2, Groups C and
D; Class II, Divisions 1 and 2, Groups E, F,
and G Ignition Temperature Code No. T3C,
320°F (160°C).
 lass I, Divisions 1 and 2, Groups B, C,
C relay (not available for outdoor, washdown
and D; Class II, Divisions 1 and 2, Groups
E, F, and G Ignition Temperature Code No.
T3C, 320°F (160°C).
● 2. Duct heaters shall have automatic and manual
reset thermal cutouts for redundant overtemperature
protection, fan relay for airflow interlock,
de-energizing controlling and backup magnetic
Typical 227 Series Duct Heater Schedule
Supply Line Duct Dimensions (Inches)
Tag No. KW Stages Special Features
Volts Phase W (Width) H (Height)
DH1 10 480 3 1 18 12 Built-on disconnect switch
DH2 15 480 3 1 36 18 Corrosion resistant
50 DH3 75 480 3 1 48 24 construction
contactors, 24 volt control circuit transformer,
terminal blocks for field wiring and supplementary
fusing for heaters over 48 amps. Controls shall be
housed in a NEMA 7, 9 cast aluminum enclosure.
● 3. The heat exchanger shall be liquid-to-air
design, utilizing a copper tube core with integral
aluminum fins. Nontoxic, inhibited, propylene glycol
heat transfer fluid shall be used that provides freeze
protection down to –49°F (–45°C). Pressure relief
valve setting to be 70 psig. The heat exchanger shall
include industrial grade HEATREX electric heating
elements.
● 4. Duct heaters shall be furnished with the
control option indicated below (select one):
 ingle stage on/off control with field
S
installed thermostat.
 olid-state control with built-in zero-
S
cross switching SCR and field installed
thermostat.
5. The following options are to be included:
 orrosion resistant stainless steel
C
construction with iridite coated heat
exchanger, epoxy coated NEMA 4X, 7, 9
terminal box, conduit and fittings.
 uilt-on disconnect switch (not available
B
for outdoor, washdown or Group B, E, F
constructions).
 upplementary fusing for heaters drawing
S
less than 48 amps.
Warning pilot light to indicate
overtemperature or no airflow.
“ Heater On” pilot light to indicate power to
the heater.
Disconnecting magnetic contactors.
 uilt-on airflow switch in place of the fan
B
or Group B construction).
 20 volt transformer in place of 24 volt
1
transformer (not available with solid-state
SCR control.
 EMA 4, 7, 9 gasketed control box for wet
N
locations.

Explosion-proof Duct Heaters
Standard Construction
Galvanized Sheet Metal Frame includes external
flanges for field mounting and an element terminal
box. Terminals are factory-connected to control
safety components in an integral cast aluminum
explosion-proof box.
Three Levels of Safety are provided on every
heater: automatic and manual reset thermal cutouts,
plus a fan interlock relay.
The automatic reset cutout, operating through the
temperature control system, is the primary protector.
The manual reset operates a separate backup
magnetic contactor, independent of the temperature
control system. The fan interlock relay prevents the
heater from being energized, unless the fan starter
is on.
Standard Built-in Control Package includes the
following components mounted in a cast aluminum
explosion-proof enclosure:
• De-energizing control and backup magnetic
contactors.
• 24 volt control circuit transformer.
• Fan relay for heater/fan airflow interlock. Supplied
with 120V or 24V coil to match the fan starter.
• Terminal blocks for field power and control wiring.
• Grounding terminal.
• Supplemental fusing for heaters drawing more
than 48 amps.
Industrial Grade Heating Elements, built by
HEATREX, are .475” (1.21 cm) diameter to provide
extra insulation between the coil and sheath for high
voltage protection. Stainless steel fins are helically
wound onto the stainless steel sheath.
www.heatrex.com
220 Series
Control Options
Two standard control options are available:
Staged Control – Either single or multi-staged
through a step controller, which may be built-in or
remotely mounted. Each three-phase stage has a
multiple of three elements to balance the electrical
load.
Solid-State SCR Control – When temperature
must be controlled precisely, built-in SCR’s are
recommended. They are furnished with field-selected
inputs of 2200 ohms, 135 ohms, 0-10 VDC, or
4-20 mA. SCR’s have zero-cross firing to eliminate
radio frequency interference.
Installation
Complete installation instructions are furnished with
each heater. The following are some guidelines:
• The heater must be attached to external duct
flanges.
• The heater must be adequately supported. If the
duct flanges will not afford enough support, use
overhead hangers for additional support.
• Airflow must be horizontal. See page 44 for airflow
requirements.
Figure 85. 220 Series Explosion-proof Duct Heaters
Class I, Division 2
Groups C and D
Temperature Code
T3, 392°F (200°C) 51
Ratings Available
• Up to 240 KW ®�
• Up to 600V
 220 Series
Explosion-proof Duct Heaters
Table XXI
Custom Options

Option Description Code

Built-in For two through ten heating stages. Input is field-selected at 2200 ohms, 135
B
Step Controller ohm, 0-10 VDCs, or 4-20 mA.
Built-On To meet NEC requirement for a disconnect at or within sight of the heater.
D
Disconnect Switch (Not available for outdoor or washdown)
Built-on Airflow An explosion-proof differential pressure switch replaces the fan relay. Use only
P
Switch for positive pressure inside the duct. (Not available for outdoor or washdown).
Supplementary
For heaters drawing 48 amps or less. Fusing is standard above 48 amps. F
Fusing
“Warning”
Red light to indicate when a thermal cutout or airflow interlock has tripped. K
Pilot Light
“Heater On”
Green light indicates when there is power to the heater. L
Pilot Light
Disconnecting Contactors that break all ungrounded lines replace standard de-energizing
M
Magnetic Contactors contactors.
120 Volt A 120V control transformer with one leg fused replaces the standard 24V trans-
V
Control Circuit former.
NEMA 4
Explosion-proof box is gasketed for outdoor or wet locations G
Construction

Figure 86. Dimensional Drawing for 220 Series

52

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 220 Series
Explosion-proof Duct Heaters
How to Order ● 2. Duct heaters shall have automatic and manual
reset thermal cutouts for redundant overtemperature
1. Inside Duct Dimensions – Width (W) by Height
protection, fan relay for airflow interlock, de-energizing
(H) per Dimensional Drawing on page 52.
controlling and backup magnetic contactors, 24 volt
Maximum size 240” (610 cm) x 120” (305 cm).
control circuit transformer, terminal blocks for field
Other dimensions will be shown on certified print.
wiring and supplementary fusing for heaters over 48
2. KW Rating – Up to 1000 KW. amps. Controls shall be housed in a NEMA 7, 9 cast
3. Heater Voltage and Phase aluminum enclosure.

4. T
 emperature Control – Staged or SCR control. ● 3. Duct heaters shall consist of industrial grade
If staged, specify number of stages (one through HEATREX stainless steel finned tubular electric
ten). If SCR control, specify input signal. heating elements mounted in a heavy-gauge
galvanized steel frame.
5. F
 an Relay Voltage – Specify 24 or 120 volt to
match fan starter holding coil voltage. ● 4. Duct heaters shall be furnished with the
control option indicated below (select one):
6. A
 irflow Direction – Horizontal right-hand or left-
hand airflow, as defined on page 44.  ingle stage on/off control with field
S
installed thermostat.
7. A
 irflow Volume – Minimum flow in SCFM
 ulti-staged control with built-in step
M
(Standard Cubic Feet per Minute) over the
controller and field installed thermostat.
heater.
 olid-state control with built-in zero-
S
8. M
 aximum Inlet Air Temperature – Maximum
cross switching SCR and field installed
of 80°F (27°C). If inlet air will be higher, consult
thermostat.
factory.
5. The following options are to be included:
9. O
 ptions – Select from 220 Series Custom Option
codes in Table XXI. Built-on disconnect switch.
 uilt-on airflow switch in place of the fan
B
Sample Specification relay.

A sample specification can be prepared by using  upplementary fusing for heaters drawing
S
the following information. A circle has been supplied less than 48 amps.
so that you may darken those sections which you “ Warning” pilot light to indicate
require. Material which is part of the standard 220 overtemperature or no airflow.
Series Explosion-proof Duct Heater specification has “ Heater On” pilot light to indicate power to
already been darkened. the heater.
● 1. Electric explosion-proof duct heaters shall be Disconnecting magnetic contactors.
HEATREX 220 Series of the KW rating, voltage,
 20 volt transformer in place of 24 volt
1
phase, duct size and airflow direction specified in
transformer.
the schedule. They shall be Factory Mutual and CSA
Approved for:  EMA 4, 7, 9 gasketed control box for wet
N
locations.
● C
 lass I, Division 2, Groups C and D, Ignition
Temperature Code T3, 392°F (200°C)

Typical Series EP2 Duct Heater Schedule

Supply Line Duct Dimensions (Inches)

Tag No. KW Stages Special Features
Volts Phase W (Width) H (Height)
DH1 3 480 3 2 24 12 Built-on disconnect switch
DH2 10 480 3 3 36 18
DH3 15 480 3 5 72 24 Warning pilot light

53

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 Custom
Explosion-proof Duct Heaters
Construction
Heaters are generally constructed per 220 Series
(see page 57), except that element terminals as well
as control components are built into a single cast
aluminum explosion-proof enclosure.
Frame – Sized to fit the duct. Standard flanged
design recommended to support heater weight.
Slip-in also available, if necessary, to match other
equipment. Galvanized steel standard; stainless
Figure 87. Custom Duct Heater
steel optional.
Control Enclosure – NEMA 7, 9 cast aluminum
box with hinged cover houses controls and element
terminals. Weatherproof construction optional.
Heating Elements – Heavy wall, large diameter
stainless steel finned tubular elements, individually
removable for servicing.
SCR Temperature Control – SCR’s with zero-cross
firing provide precise proportional control. SCR’s
also minimize element operating temperatures for
extra safety. Optional on/off single or multi-stage
control also available.
Figure 88. Control enclosure
Overtemperature Protection – Thermocouple
controllers measure element sheath temperature.
• Automatic reset control resets when temperature
drops to a safe level.
• Manual reset control, with external button,
provides back-up protection.
Fuses – Individual circuit fusing for heaters drawing
over 48 amps to meet NEC requirements.
Airflow Interlock – Fan relay prevents heater
operation, unless fan is energized. Optional built-
in or remote explosion-proof airflow switch can be
provided.
Magnetic Contactors – Furnished as required for
temperature and safety controls.
Control Transformer – Furnished as standard with
fusing as required.

Class I, Division 1 and 2

Groups C and D
54 Class II, Divisions 1 and 2
Groups E, F, and G
Although built to hazardous safety standards,
www.heatrex.com
these heaters are not FM or CSA Approved.

Explosion-proof Duct Heaters
How to Order
1. C
 onstruction Type – Standard flanged or
optional slip-in. See Figures 89 and 90.
2. E
 lectrical Ratings – Line voltage, KW, Phase
and Control Voltage.
3. Inside Duct Dimensions – Width and Height.
4. T
 emperature Control – Staged or SCR Control.
If staged, specify number of stages (one through
ten). If SCR control, specify input signal.
5. Airflow Direction –
• Horizontal (Right or Left).
• Vertical (Up or Down).
6. A
 irflow Volume – Minimum flow in SCFM
(Standard Cubic Feet per Minute) over the
heater.
7. M
 aximum Inlet Air Temperature – Maximum
of 80°F (27°C). If inlet air will be higher, consult
factory.
8. C
 lassification of Hazardous Area – Class,
Group, Ignition Temperature and NEC I.D. Code
No.
9. O
 ptions – Select from 220 Series Custom Option
codes in Table XXI on page 52.
Figure 89. Standard flanged heater installation
Figure 90. Optional slip-in heater installation
Custom
Sample Specification
A sample specification can be prepared by using
the following information. A circle has been supplied
so that you may darken those sections which you
require. Material which is part of the standard Custom
Explosion-proof Duct Heater specification has already
been darkened.
● 1. Electric explosion-proof duct heaters shall be
HEATREX custom explosion-proof, the KW rating,
voltage, phase, duct size, construction type and airflow
direction specified in the schedule. They shall be
approved for:
 lass I, Divisions 1 and 2, Groups C and
C
D, and NEC Ignition Temperature I.D. Code
Number ________ (please specify).
 lass II, Divisions 1 and 2, Groups E, F, and
C
G, and NEC Ignition Temperature I.D. Code
Number ________ (please specify).
● 2. Duct heaters shall have automatic and manual
reset thermal cutouts for redundant overtemperature
protection, fan relay for airflow interlock, de-energizing
controlling and backup magnetic contactors, 120 volt
control circuit transformer, terminal blocks for field
wiring and supplementary fusing for heaters over 48
amps. Controls shall be housed in a NEMA 7, 9 cast
aluminum enclosure.
● 3. Duct heaters shall consist of industrial grade
HEATREX stainless steel finned tubular electric
heating elements mounted in a heavy-gauge
galvanized steel frame.
● 4. Duct heaters shall be furnished with the control
option indicated below (select one):
 ingle stage on/off control with field installed
S
thermostat.
 ulti-stage control with built-in step controller
M
and field installed thermostat.
 olid-state control with built-in zero-cross
S
switching SCR and field installed thermostat.
5. The following options are to be included:
Built-on disconnect switch.
 upplementary fusing for heaters drawing
S
less than 48 amps.
 arning pilot light to indicate overtemperature
W
or no airflow.
“ Heater On” pilot light to indicate power to the
heater.
Disconnecting magnetic contactors.
Built-on airflow switch in place of the fan relay.
 4 volt transformer in place of 120 volt
2
55
transformer.
NEMA 4, 7, 9 gasketed box for wet locations.
 Typical Wiring Diagrams

Illustrated on these pages are typical wiring diagrams for HEATREX open coil and finned tubular duct heaters.

Wiring diagrams shipped with many heaters are semi-typical in nature, showing various alternates for certain compo-
nents and illustrating Special Features which may not be supplied on the heater in question. However, check blocks on
each wiring diagram are marked to indicate which of the alternates or Special Features apply. The wiring diagrams also
indicate the appropriate field wiring gauges and the amp rating of any fuses provided.

Control Option G, Single Stage Three-Phase

Open Coil Finned Tubular

Diagram-1 Diagram-2

Control Option G, Single Stage with Fan Relay,Three-Phase

Open Coil Finned Tubular

Diagram-3 Diagram-4

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 Typical Wiring Diagrams

Control Option G, Multiple Stages, Single-Phase

Open Coil Finned Tubular

Diagram-5 Diagram-6

Control Option G, Multiple Stages with Electronic Step Controller, Three-Phase

Open Coil Finned Tubular

Diagram-7 Diagram-8

Control Option K, SCR, Three-Phase

Open Coil Finned Tubular

Diagram-9 Diagram-10
57

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 Typical Wiring Diagrams
Standard Control Options
Control Option K, with a Proportional Room or Duct Thermostat, Three-Phase
Open Coil Finned Tubular

Diagram-11 Diagram-12

Control Option K, SCR Vernier Control, Three-Phase

Open Coil Finned Tubular

Diagram-13 Diagram-14

Control Option K, SCR Vernier Control, Remote Control Panel, Three-Phase

Open Coil Finned Tubular

Diagram-15 Diagram-16
58

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 HEATREX Products
Standard Control Options
238 Series Industrial Unit Heaters
• Ratings from 3 KW through 38 KW.
• Stainless steel finned tubular heating elements.
• Adjustable discharge louvers.
• Bracket for ceiling or wall mounting.
• Built-in controls.
• cULus Listed.

234 Series Washdown and Corrosion

Resistant Unit Heaters
•  tainless steel construction with NEMA 4X enclosure.
S
• Built-in controls.
• Swivel mounting bracket.
• Ratings up to 47 KW.
• cULus Listed and ABS Approved.

233 Series Explosion-proof Unit Heaters

• 2
 33 Series has the industry’s lowest ignition
temperature code rating.
• Class I & II, Divisions 1 & 2, Groups C, D, E, F & G.
• Built-in controls.
• Small, economical COMPACT designs up to 12 KW.
• Factory Mutual (FM), CSA, ABS Approved.

254 Series Explosion-proof Convectors

• Class I & II, Divisions 1 & 2,
Groups B, C, D, E, F & G.
• Ratings from 500 to 9,500 watts.
• Sloped-top cabinet design.
• Available with built-in controls.
• Factory Mutual (FM), CSA, ABS Approved.

59

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 HEATREX Products

Comfort Heating Products

Forced -Air Heaters
• Cabinet unit heaters range from 2,000 to 24,000 watts. Units
may be mounted on the floor, wall or ceiling, and can be
recessed for wall or ceiling applications. Full line of optional
features available.
• Commercial and architectural wall heaters available from
2,000 to 12,000 watts.
• Ceiling heaters for surface, T-Bar, or recessed mounting
with voltage up to 480 VAC, 3-phase and up to 10,000
watts.

Baseboard Heaters
• Heavy-duty baseboard heaters for commercial, architectural,
or industrial applications. Available in flat or sloped top
design with a durable epoxy/polyester powder paint finish
on a heavy gauge aluminum and steel cabinet. Sizes range
from 300 to 4,000 watts.
• Architectural convectors provide large amounts of heat
without the fan noise associated with the unit heaters. Can
be floor or wall mounted, and fully recessed with a front
warm air outlet.

240 Series Unit Heaters

• Heavy-duty commercial unit heaters, offered to 50KW,
can be mounted horizontally or vertically. Each heater is
available with both ceiling and wall mounting brackets for
easy installation.

60

www.heatrex.com

Industrial Engineering and Equipment Company
(HEATREX) products are warranted against defects in
workmanship, material, design, labeling and packaging.
No other warranty, expressed or implied, written or oral,
applies. No person other than an officer or the general
manager of HEATREX is authorized to give any other
warranty or assume any liability.
Warranty Period: This warranty is effective for eighteen
months from the date of shipment of the product from
HEATREX’s factory, or for twelve months from the date
the product is first placed in service, whichever period
lapses first.
Conditions of Warranty: HEATREX products must
be installed, operated and maintained in accordance
with HEATREX’s instructions. HEATREX is not liable
for damage or unsatisfactory performance of the
product resulting from accident, negligence, alteration,
unauthorized repair, improper application or installation
of the product, improper specifications or corrosion.
HEATREX IS NOT LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES. Claims against carriers
for damage in transit must be filed by the purchaser with
the carrier.
Limited Warranty
Remedy: The part or product in question should be
returned, freight prepaid, to:
HEATREX
425 Hanley Industrial Court
St. Louis, Missouri 63144
Attention: Return Materials Manager
If after receipt of the product and the claim, HEATREX
finds to its reasonable satisfaction that the product is
defective in workmanship, material, design, labeling
or packaging, the product will be repaired or replaced
or the purchase price refunded at HEATREX’s option.
There will be no charge to the purchaser for parts or
labor. Removal and reinstallation of the product, and
shipment of the product to HEATREX for repair or
inspection shall be at the purchaser’s risk and expense.
THE REPAIR, REPLACEMENT OR REFUND
PROVIDED FOR IN THIS LIMITED WARRANTY IS
THE EXCLUSIVE REMEDY OF THE PURCHASER.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY
OTHER WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING ANY WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE. THERE
ARE NO WARRANTIES WHICH EXTEND BEYOND
THE TERMS OF THIS LIMITED WARRANTY.
 314-333-5500
www.HEATREX.com

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